In this study, the influence of laser shock peening as a post-treatment on cold-sprayed Inconel 625 deposits is investigated to demonstrate the effects of inducing plastic deformation and residual stresses by LSP in order to heal out non-bonded interfaces within the coatings.

This work specifically focuses on time-averaged centerline bow shock standoff distance (Δ) which serves as a simple descriptor of the complex impinging jet flow field. Synthesis of physical and computational experiments conclusively demonstrates that a commonly cited correlation in cold spray literature involving Δ is quantitatively valid for the case of supersonic flow over stationary spheres, which is the situation for which this correlation was specifically developed. However, the present work shows that this correlation is quantitatively and qualitatively invalid for supersonic jet impingement flows relevant to CS.

In this work, cold spray shot peening was used to treat interstitial-free (IF) steel. Different numbers of impact passes were evaluated and the microstructure and hardness evolution in IF steel were analyzed. Based on the experimental results, the potential of CSSP to achieve surface strengthening and properties enhancement in metallic materials is demonstrated.

Numerical studies directly quantifying particle-substrate adhesion under different spray process parameters during impact remain scarce, primarily due to the lack of consideration for adhesion models. This study addresses this gap by investigating bonding behavior under varying spray conditions using a single-particle model with the PD numerical method, incorporating adhesion forces.

In this study, we investigated a novel approach using the cold spray process to develop ferromagnetic components. To assess the feasibility and performance of these components, their mechanical and magnetic properties were analyzed through various experiments and measurement techniques. Different FeNi50 powder sizes were considered, and a range of deposition conditions were applied to examine their effects on porosity, deposition efficiency, microstructure of the final structure, and magnetic field properties.

This paper aims to develop a multiparameter-based three-dimensional simulation tool for cold spray, designed to predict material deposition behavior in real-world processes under varying process parameters and workpiece geometries.

We expand on our previous numerical framework to account for and study strain-induced thermal effects in cold spray bonding. The new enhancement considers the work of plastic strain, G , as the driving mechanism behind bonding and strain-induced heat. Only a portion of G , called the stored energy of cold work, contributes to bonding, with the remaining portion resulting in an adiabatic increase in temperature.

This study examines the effects of N 2 and He process gases and heat treatment on the microstructure and mechanical properties of 3D-printed pure copper produced using a low-pressure cold spray system. Microstructural analysis is performed through optical microscopy, while tensile tests are used to evaluate mechanical properties. Samples processed with N 2 demonstrate improved plastic deformation, leading to reduced porosity compared to those processed with He.

In this study, we focus on developing effective repair procedures by optimizing key processing parameters such as gas pressure, gas temperature, and traverse speed. To achieve this, a combination of machine learning and experimental testing was employed on cold-sprayed Ni-based superalloy (IN 625). The prepared samples were assessed for microhardness, adhesion strength, and porosity, and these experimental results were subsequently used to train a machine learning model. This model predicts material properties under varying process conditions, ensuring precision in parameter selection.

This study investigates the cold gas spraying (CGS) process as an innovative approach for fabricating cBN-copper composite coatings. CGS, a low-temperature thermal spray and additive manufacturing process, prevents thermal degradation of sensitive materials such as cBN and ensures a dense coating with a high bond strength. The research focuses on key parameters such as primary gas temperature and pressure as well as the ratio of cBN to copper, analyzing their effects on coating performance.

This research proposes an experimental methodology towards visually observing high strain rate polymer deformation characteristics at scales relevant to cold spray particle impacts. Macro-scale (~ 3 mm) polymer impact testing via a light gas gun has shown evidence of cold spray indicative features at certain (material, particle/substrate temperature, velocity, etc.) conditions.

For this study, a fixed high-end primary parameter set with respect to gas pressure and temperature was selected for depositing Al6061 powder feedstock on Al6061-T6 substrate sheets. The influences of different parameter variations on spray deposit build-up and performance were investigated by evaluations of deposit efficiency, deposit microstructures, porosities, deposit hardness, and electrical conductivity.

In this research work, MoNbZrTiV and AlNbTaTiV refractory high-entropy alloy (RHEA) material combinations were investigated as potential candidates for feedstock materials for cold spray additive manufacturing. The two RHEA materials as precursors for developing micron-sized particles were alloyed mechanically through high-energy ball milling following a rigorous material design-of-experiments curriculum on account of elemental melting point differences. Detailed particle characterization techniques were employed to gain insights into the RHEA particle properties.

Concrete in cold seawater suffers from freeze-thaw damage (cracking, scaling) and steel corrosion (chloride penetration), increasing maintenance and risking failure. To improve protection, this study investigates a multilayered coating: a sealant top layer over a thermally sprayed zinc bond layer. The coating's long-term durability was tested under icing conditions before and after 96 hours of salt spray. Results show the multilayered coating's icephobic properties remained stable despite corrosion exposure, suggesting it can enhance the lifespan of concrete in harsh marine environments.

This work aims to evaluate the viability of laser heat treatments as a method to recover cold-sprayed coating ductility, i.e., to achieve with laser heat treatment a gain in elongation equivalent to a furnace heat treatment. A 4kW YAG laser was employed to heat treat 4-5 mm thick coldsprayed copper coatings produced on coupons and on prototypes of large components. Surface temperatures were monitored during the heat treatment using an infrared camera. Hardness and tensile properties were measured on as-sprayed and heat-treated coatings. Microstructural examinations provided additional insights to explain the properties evolution during heat treatment.

In this paper, we evaluate the potential of ultrasonic atomization as a new feedstock manufacturing technique for cold spray by comparing the cold spray performance of an experimental stainless steel 316L powder obtained from ultrasonic atomization with a commercial stainless steel 316L powder produced through gas atomization.

This study investigates improving the adhesion of bell metal repairs using substrate surface treatment. Copper-tin alloy (Cu20Sn) powder was deposited onto Cu20Sn substrates with various surface treatments, including ground, polished, cold spray (CS)-blasted, and laser-textured surfaces. Adhesion was tested using a bending method adapted for thick CS deposits. Results showed that CS-blasting achieved approximately 70 MPa adhesion, while laser texturing yielded up to 120 MPa.The adhesion strength was partially related to the adhesion area ratio, and fractographic analysis revealed the failure mechanisms for each treatment.

This study focuses on a novel online cold spray process monitoring system that uses in-situ diagnostics during cold spraying and cold spray additive manufacturing. It combines the in-flight behavior of particles with the expected properties of the resulting coatings.

In this study, the two primary goals were: (i) to investigate the impact of laser ablation parameters on the physio-chemical nature and surface texture of the substrate, and (ii) to identify the optimal laser parameters to maximize the coating's adhesion to the substrate.

This research aims to enhance the deformability of Inconel 718 by modifying the feedstock microstructures prior to deposition through solution treatment process at 950 °C and 1050 °C. It was observed that the gamma phase has transformed into a stable delta precipitate at 950 °C. Higher treatment temperature at 1050 °C shows a complete solution transition, proven by EBSD phase map, and electron channelling contrast imaging (ECCI).