This paper represents an effort to systematize an understanding of the cold spray process and the suitability of material for such a process. The evaluation is based on a brief analysis of the powder particle impact and a literature research concerning shock compression phenomena in matter and related physical effects, such as impact heating and dynamic yielding. The FEM simulations performed permit estimating the maximum impact pressures, the deformation rates and the deformation kinetics during impact. The calculations can be verified experimentally and are supported by the data published. From a brief analysis of the equations of state applied to shock compression, key material parameters are derived and investigated. A parameterization of physical properties and correlation with the crystal types endeavors to provide a ranking of material suitability.

Atmospheric Rheo-Spraying (ARS) using the HVOF process enables injection-molded structures and thick-film coatings from steels and from high-temperature Ni-based alloys with layer thicknesses down to the centimeter. The ARS process control is based on the thermal spraying of particles in the solid state at a maximum average speed of more than 600 m/s. The coating consolidation to porosity values below 1% occurs through the particle impact with high kinetic energy. Because of the low particle oxidation, the mechanical properties of the heat-treated injection-molded structures are comparable to those of forged alloys. In this paper, ARS injection molding is successfully implemented in combination with an innovative manufacturing technique in rocket engine technology to produce a model composite combustion chamber with a thermally sprayed internal pressure jacket. Paper includes a German-language abstract.