Cold Spray (CS) has gained special interest as a coating method due to the production of low oxide content deposits and solid-state deposition of powder material. This paper investigates the interaction between an electromagnetic field and cold-sprayed coatings produced using an induction heating cold spray (IHCS) system. It also investigates the role of the initial substrate surface temperature. The soft/hard material combination was used for depositing pure aluminum on Ti64 substrates. To assess the performance of the IHCS technique, deposition efficiency and adhesion and tensile strengths were used to characterize the hybrid technique. The results were compared to the traditional CS process. It was observed that the IHCS tensile samples exhibited almost three times the average elongation at break obtained by the traditional CS process. Intra-particle surface fracture was found in the samples produced by the hybrid process.

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