This paper reviews the capabilities of portable low pressure cold spraying systems and presents examples of the repairs that have been made and the different materials involved. It discusses the recent development of ceramic nozzle inserts that extend continuous operating time to more than 10 h and non-pressurized rotating-vibratory powder feeders that provide higher, more stable powder feed rates for production environments.

The main advantage of the cold spray process is minimal influence on the substrate properties with sufficiently high bond strength. This advantage allows metal coating to be applied to the specific objects which were never subjected to the thermal spray process. The examples of the low pressure cold spray application to the glass objects, magnet sensors and electronic elements are presented and discussed.

The heating of the substrate by the jet may influence on the process of coating deposition by DYMET technology. It can be observed as deposition efficiency variation at various nozzle transverse speeds. Experimental investigation of the deposition efficiency variation for different jet stagnation temperatures and different substrate thermal properties is presented and discussed. The suppression of substrate influence on the deposition process with the coating thickness growth is demonstrated.

High density and low porosity of gas dynamic sprayed coatings may provide gases and liquids impermeability. But jet deflection and stagnation in the narrow splits and reach-through holes prevent from sealing up the deep substrate defects by gas dynamic spray. The correct choice of powder blend makes the gas dynamic spray process applicable to the splits and holes sealing up. The approaches to the defects sealing up by gas dynamic spray and some applications are presented and discussed.

High requirements of Cold Gas Dynamic Spray (GDS) process caused the development of low pressure DYMET technology. The technology and equipment evolution is presented and discussed. Modern portable low pressure DYMET equipment may be easily applied for various technical problem solutions. Multiple applications are briefly described.

Dynamic Metallization (DYMET) process is developed to produce thick aluminum, copper, zinc, nickel, cobalt, lead, and tin coatings on any metal or ceramic substrates. It consists of a surface treatment process in which a mixture of solid metal and ceramic powders are accelerated by compressed air at pressures between 0.5 and 0.8 MPa.