A new process, the Pulsed-Cold Gas Dynamic Spraying process is presented in this work. A description of the process and of the experimental set-up developed at the University of Ottawa Cold Spray Laboratory is presented. It is envisioned that this process could allow for the feedstock particles to be accelerated to high impact velocities and intermediate temperatures, in a non-reacting gas. That way, the intermediate particle impact temperature would lead to a lower critical velocity as compared with CGDS that could be easily reached while preserving the chemical and microstructural composition of the feedstock particles in the coating. Selected examples of the variety of coatings produced with the system are presented, illustrating the potential of the process to deposit various materials as well as its main benefits.

The proposed work describes recent efforts to develop metastable Al-Fe-V-Si coatings for internal-combustion engine applications with higher mechanical properties at high operating temperatures. To do so, the metastable solid powder alloy was engineered from rapid solidification technique (namely gas atomization). The metastable alloy powder was deposited using the Cold Spray process in order to produce protective coatings on top of existing parts. The critical velocity, above which Cold Spray deposition takes place, was successfully achieved and Al-Fe-V-Si coatings were produced. The microstructure of the feedstock powder was retained in the coatings produced, showing the potential of the Cold Spray process to produce metastable coatings for internal combustion engine applications.