Abstract
In this study, cold sprayed Ni is deposited on Al substrates using different gas pressures. Spherical Ni powder was sprayed on cylindrical substrates using argon as the powder carrier and compressed air as the propellant. Coating and splat surfaces and cross-sections were examined, adhesion strength was measured, and particle velocity and temperature were determined through CFD simulations. The results show that denser, more well adhered coatings were obtained under higher propellant pressure. Higher gas pressure increases particle velocity, which intensifies material deformation and the disruption of surface oxides in the impact area, resulting in greater metallurgical bonding between the splats and the substrate. The formation of Ni-Al intermetallic phase at the interface region due to heat treatment was confirmed and its effect on bonding strength is discussed.
