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1-20 of 771
Cold spray coating
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Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 1-6, May 5–8, 2025,
Abstract
View Papertitled, Modification of Cold Sprayed Inconel 625 Deposits by Laser Shock Peening
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for content titled, Modification of Cold Sprayed Inconel 625 Deposits by Laser Shock Peening
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.
Proceedings Papers
Considerations for Estimating Bow Shock Stand-Off Distance in Cold Spray Supersonic Jet Impingement
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ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 31-37, May 5–8, 2025,
Abstract
View Papertitled, Considerations for Estimating Bow Shock Stand-Off Distance in Cold Spray Supersonic Jet Impingement
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for content titled, Considerations for Estimating Bow Shock Stand-Off Distance in Cold Spray Supersonic Jet Impingement
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 68-73, May 5–8, 2025,
Abstract
View Papertitled, Surface Strengthening of Steel by High-Velocity Cold Spray Shot Peening
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for content titled, Surface Strengthening of Steel by High-Velocity Cold Spray Shot Peening
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 74-79, May 5–8, 2025,
Abstract
View Papertitled, Numerical Prediction of Critical Velocity and Spray Angle Windows for Particle Adhesion in Cold Spray Using Peridynamic Simulations
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for content titled, Numerical Prediction of Critical Velocity and Spray Angle Windows for Particle Adhesion in Cold Spray Using Peridynamic Simulations
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.
Proceedings Papers
Magnetic Performance and Microstructural Characterization of Cold Sprayed Ferromagnetic Materials
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ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 87-92, May 5–8, 2025,
Abstract
View Papertitled, Magnetic Performance and Microstructural Characterization of Cold Sprayed Ferromagnetic Materials
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for content titled, Magnetic Performance and Microstructural Characterization of Cold Sprayed Ferromagnetic Materials
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 112-119, May 5–8, 2025,
Abstract
View Papertitled, Deposition Simulation for an Automated Cold Spray Additive Manufacturing Process
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for content titled, Deposition Simulation for an Automated Cold Spray Additive Manufacturing Process
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 137-144, May 5–8, 2025,
Abstract
View Papertitled, The Role of Strain-Induced Heat in Cold Spray Bonding: A Numerical Study
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for content titled, The Role of Strain-Induced Heat in Cold Spray Bonding: A Numerical Study
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 145-152, May 5–8, 2025,
Abstract
View Papertitled, Enhancement and Validation of Diagnostic Systems for the Measurement of Particle Properties in High-Kinetic Thermal Spray Processes
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for content titled, Enhancement and Validation of Diagnostic Systems for the Measurement of Particle Properties in High-Kinetic Thermal Spray Processes
In this study, two particle-tracking velocimetry systems, the Oseir HiWatch HR2 and the Oseir HiWatch CS2 were tested. The particle-sizing velocimetry results were then compared with corresponding particle characteristics obtained using a Tecnar Cold Spray Meter and a Tecnar Accuraspray 4.0 unit. In addition, particle size distributions measured by laser diffraction were included for validation.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 153-158, May 5–8, 2025,
Abstract
View Papertitled, Influence of Carrier Gas and Post-Heat Treatment on the Microstructure and Tensile Properties of 3D-Printed Cold Spray Copper
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for content titled, Influence of Carrier Gas and Post-Heat Treatment on the Microstructure and Tensile Properties of 3D-Printed Cold Spray Copper
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 206-213, May 5–8, 2025,
Abstract
View Papertitled, Machine Learning Optimization of IN625 Coating Properties in Cold Spray Process
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for content titled, Machine Learning Optimization of IN625 Coating Properties in Cold Spray Process
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 221-229, May 5–8, 2025,
Abstract
View Papertitled, Influence of Design and Thermal Spraying Methods on the Techno-Economic Outcomes of a Coating-Based Deicing System for Mitigating Frozen Pipe Incidents
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for content titled, Influence of Design and Thermal Spraying Methods on the Techno-Economic Outcomes of a Coating-Based Deicing System for Mitigating Frozen Pipe Incidents
The present study explores the feasibility of utilizing both cold and flame spray processes to fabricate the latest version of the resistive heating coating-based system for steel pipes, focusing on a straightforward design that minimizes material and labor costs.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 295-301, May 5–8, 2025,
Abstract
View Papertitled, Towards Visually Observing Viscoelastic Behavior in Polymer Cold Spray Using Ultra High-Speed Videography
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for content titled, Towards Visually Observing Viscoelastic Behavior in Polymer Cold Spray Using Ultra High-Speed Videography
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 302-309, May 5–8, 2025,
Abstract
View Papertitled, Influence of Secondary Parameters in Cold Gas Spraying of 6061 Aluminum
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for content titled, Influence of Secondary Parameters in Cold Gas Spraying of 6061 Aluminum
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 316-321, May 5–8, 2025,
Abstract
View Papertitled, Particle Investigation of Mechanically Alloyed Refractory High-Entropy Alloy as Feedstock for Cold Spray Additive Manufacturing
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for content titled, Particle Investigation of Mechanically Alloyed Refractory High-Entropy Alloy as Feedstock for Cold Spray Additive Manufacturing
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 391-397, May 5–8, 2025,
Abstract
View Papertitled, Cold Sprayed Bell Metal: Improving Adhesion by Substrate Laser Surface Texturing
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for content titled, Cold Sprayed Bell Metal: Improving Adhesion by Substrate Laser Surface Texturing
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 406-412, May 5–8, 2025,
Abstract
View Papertitled, Online Cold Spray Process Monitoring by Real Time Diagnostics
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for content titled, Online Cold Spray Process Monitoring by Real Time Diagnostics
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 413-419, May 5–8, 2025,
Abstract
View Papertitled, Influence of Pulsed Laser Ablation Parameters on Adhesion of Cold Spray Al6061 Coatings on Extruded Al6061 Substrates
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for content titled, Influence of Pulsed Laser Ablation Parameters on Adhesion of Cold Spray Al6061 Coatings on Extruded Al6061 Substrates
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.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 420-427, May 5–8, 2025,
Abstract
View Papertitled, Feedstock Modification and Microstructural Characterization of Cold Spraying of Inconel 718
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for content titled, Feedstock Modification and Microstructural Characterization of Cold Spraying of Inconel 718
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).
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 484-491, May 5–8, 2025,
Abstract
View Papertitled, Key Factors Governing the Deposition of Hard Phases When Cold Spraying Metallic Matrix with Mechanically Mixed Powders
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for content titled, Key Factors Governing the Deposition of Hard Phases When Cold Spraying Metallic Matrix with Mechanically Mixed Powders
Cold spraying mixed metal-ceramic powders creates metallic matrix composites, but typically achieves low hard phase content in deposits. We investigated this challenge using various hard phases (SiC, diamond, WC, W) with Al and Cu metal matrices. Our results reveal that density difference—not hardness—between components primarily determines deposition efficiency. When using Al with similarly dense materials (diamond, SiC), deposit compositions remained comparable despite hardness variations. However, mixing Al with 50 vol.% of WC or W produced deposits containing 57.9 vol.% and 79.8 vol.% hard phases, respectively. Based on these findings, we established a ballistic theory-based criterion for effective hard particle deposition.
Proceedings Papers
Development of Dense and Low Oxide Titanium Coatings for PEMWE Application
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ITSC2024, Thermal Spray 2024: Proceedings from the International Thermal Spray Conference, 1-7, April 29–May 1, 2024,
Abstract
View Papertitled, Development of Dense and Low Oxide Titanium Coatings for PEMWE Application
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for content titled, Development of Dense and Low Oxide Titanium Coatings for PEMWE Application
A key technology to minimize CO 2 -emissions is the production of hydrogen from water electrolysis. The proton exchange membrane water electrolysis (PEMWE) consists of a stacked system out of bipolar plates (BPP), porous transport layers (PTL) and a membrane electrode assembly (MEA). Research activities are ongoing to minimize material input, reduce costs and increase the performance. For example, the BPP on the anodic side of the stack is currently manufactured of bulk titanium and its substitution by a Ti-coated steel substrate is economically interesting. The main requirements for the BPP-coating are a high coating density, a low electrical resistance and a long lifetime in a harsh electrochemical environment. Coating application on substrates of s ≤ 0.5 mm thickness is conducted with three thermal spraying technologies: Cold Gas Spraying (CGS), High Velocity Air-Fuel (HVAF) spraying and High Velocity Oxy-Fuel (HVOF). Substrate preparation is examined as well. Coating development is conducted with regards to coating thickness, density and oxidation. The examination of coatings includes roughness analysis, structural and chemical analysis. The results allow an evaluation of the suitability of thermally sprayed Ti-coatings by the structural properties for the PEMWE application. Among the three tested processes, CGS is the most suitable for this type of application. The three chosen thermal spraying processes are examined for coating application on metal sheets in context of PEMWE for the first time.
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