Various metals such as aluminum, copper, zinc, steel, nickel, titanium, and niobium have been deposited on a wide range of substrate materials via cold spraying. This paper provides a detailed overview of the cold spray process and the coatings typically produced. It discusses the powders and gases used, the dynamics of gas-particle flow in spray nozzles, the effect of temperature and pressure, and the concept of critical velocity. It also presents examples of the properties and microstructures recently achieved in cold sprayed aluminum, zinc, NiCr, MCrAlY, and Cu-Al coatings. Paper includes a German-language abstract.

This paper provides an overview of the equipment used in cold gas spraying. It discusses the general design and operation of key components, including the nozzle, the control system, the gas heater, and powder feeder. It also describes a typical gas supply system, the recycling of helium, and the provisions for health and safety that are necessary in a spray booth. Paper includes a German-language abstract.

A number of studies have been conducted over the past few years with the aim of modeling high-speed particle-substrate interactions during cold spraying. This paper summarizes the work conducted and some of the more important findings. Based on experimental measurements and dynamic deformation modeling, it is shown a radial jet of metal forms at the contact zone during cold spraying. The effect is similar to that observed in explosive welding and it leads to corona-shaped ejection of metal at the periphery of the contact zone. Paper includes a German-language abstract.

Cold spray nozzles can have a significant impact on particle behavior and coating quality depending on their shape and size. This study investigates the influence of nozzle geometry on the cold spray process. Simulations show that particle velocities are highest at the outlet of de Laval type nozzles and that convergence pipe nozzles achieve the highest particle temperatures. Paper includes a German-language abstract.