In the last years, results of many studies have been published contributing to enhance the understanding of the fundamental mechanisms of cold spray coating generation and bonding, as well as coating characteristics. From the point of view of a job shop in thermal spraying and a user of cold spraying equipment, the procedure in development of new applications is presented. Besides the technical requirements, some general factors determining the success of industrial use of cold spraying are shown. Examples of cold sprayed coatings are described to show on one hand the possibility of a fast integration of this new technique in established coating jobs and on the other hand the exploration and use of the new possibilities of cold spraying and the development of applications, which still have not been in the focus of thermal spraying. Suggestions to further research and development activities are made on the base of practical cold spray experience.

A promising technique to increase the portions of hard metal and hence the wear resistance of components is the coating with more wear-resistant hard metals by thermal spraying. The development of suitable coatings includes the selection of substrates, preliminary treatment of substrates, selection of powders, spraying techniques, spraying parameters, coating and quality characterisation. Examined were variants of high velocity oxy-fuel flame spraying CDS (Continuous-Detonatio-Spraying), DJH (Diamond-Jet-Hybrid 2700) and the wear resistance with 3-body-wear. The results confirm that substrates coated by DJH hard metal (e.g. with WC 86 Co10 Cr4) in comparisation with uncoated substrates (16MnCr5, case-hardened, hardness 65 HRC) have a specific wear by 3-body-wear-test which is many times lower then without coating. Paper text in German.