This chapter provides an overview of the state of the art in high-pressure cold spray equipment, including both spray systems and gas supply systems. The chapter describes the commercial cold spray systems developed by companies such as Cold Gas Technology (CGT) GmbH, Plasma Giken Company Ltd, Impact Innovations GmbH, and ASB Industries. Typical helium and nitrogen gas systems used in high-pressure cold spray processing are reviewed.

Increasing growth of high-pressure cold spraying applications on the industrial scale have forced global powder producers to face this challenge and develop specific powders for cold spray applications. This chapter provides information on the properties, classification, characteristics, manufacturing, and procedures for packaging of powders specific to cold spray applications.

Cold spray is a process technology that, for the first time, enables the rapid deposition of a wide range of metals and some other materials in the solid state at temperatures far below their melting points. This chapter provides an overview of the processes involved in cold spray process technologies, namely high-pressure cold spray (HPCS) and low-pressure cold spray (LPCS), explaining differences of LPCS from HPCS. It summarizes the historical background of the cold spray process. The growing international interest in the cold spray process from the early 2000s is also reviewed.

This chapter focuses on high-pressure cold spray applications pertaining to repair and refurbishment in the aerospace, oil and gas, and power-generation industries, the last specifically involving repair of gas turbine components. Advantages of cold spray coating in the repair and refurbishment of structural engineering components are also discussed.

This chapter discusses the application of high-pressure cold spray to the automotive industry field, with special attention to three applications: additive manufacturing, fabrication methods, and protective coatings. Various studies on the automotive application of cold spray are reviewed. The background and purpose of each application are presented and practical cases are discussed.

High-pressure cold spray repair process has been used on a number of different applications in the defense industry. This chapter describes various applications for cold spray systems that have operating pressures greater than 2.4 MPa (350 psi) and operating temperatures greater than 500 deg C (930 deg F).

The modeling and simulation activities in the field of high-pressure cold spray can be divided into two main parts: solid mechanics and fluid dynamics. This chapter focuses on these parts of modeling work in cold spray research. The discussion covers the objective, principal concepts, methods, and outcome of modeling and simulation of particle impact and of in-flight history of particles in cold spraying. The concept of integration of particle impact and fluid flow modeling to optimize cold spray deposition for a given material is also explained.

This chapter reviews the current understanding of high-pressure cold spraying for different materials, covering widely accepted general mechanisms for particle deposition and the processes and parameters involved. It begins by reviewing the mechanisms of bonding. An overview of the optimization of the critical process parameters for improving coating qualities is then provided. This is followed by a separate section dealing with bonding between different materials and addressing influences on adhesion to the substrate as well as the cohesion between dissimilar coating constituents. The knowledge of the basic science and mechanisms finally allows for discussion on the requirements for suitable cold spray equipment and of the parameter sets needed for successful coating deposition.

This article provides a brief description of commercially important thermal spray processes and gives examples of applications and application requirements. The processes covered are flame, wire arc, plasma, high-velocity oxyfuel processes, detonation gun, and cold spray methods. Examples are provided of the applications in aerospace, automotive, and medical device industries as well as the use of thermal spray as an additive manufacturing technique.

This article summarizes the results of work completed by the ASM Thermal Spray Society Advisory Committee to identify key research challenges and opportunities in the thermal spray field. It describes and prioritizes research priorities related to emerging process methods, thermal spray markets and applications, and process robustness, reliability, and economics.

This chapter elucidates the indispensable role of characterization in the development of cold-sprayed coatings and illustrates some of the common processes used during coatings development. Emphasis is placed on the advanced microstructural characterization techniques that are used in high-pressure cold spray coating characterization, including residual-stress characterization. The chapter includes some preliminary screening of tool hardness and bond adhesion strength, as well as a distinction between surface and bulk characterization techniques and their importance for cold spray coatings. The techniques covered are optical microscopy, X-Ray diffraction, scanning electron microscopy, focused ion beam machining, electron probe microanalysis, transmission electron microscopy, and electron backscattered diffraction. The techniques also include electron channeling contrast imaging, X-Ray photoelectron spectroscopy, X-ray fluorescence, Auger electron spectroscopy, Raman spectroscopy, oxygen analysis, and nanoindentation.

This article provides a high-level overview of thermal spray technologies and their applications and benefits. It is intended to educate members of government, industry, and academia to the benefits of thermal spray technology. The article describes the value of thermal spray technology with examples of application success stories. A few applications critical to thermal spray and market growth are briefly discussed. The article also summarizes the key research areas in thermal spray technology.

This chapter provides an overview of aluminum die casting and the equipment used. It discusses the advantages and limitations of the die casting process and the design and operation of hot- and cold-chamber die casting machines. It also discusses clamping systems and forces and the factors affecting die life, including die materials, metal injection cycles, and lubrication. A typical die casting cell layout is also provided.

Abradable coatings (such as Ni-4Cr-4Al/bentonite) are used throughout jet engines, primarily as sacrificial coatings into which moving components wear. This article presents the Accepted Practice for sample preparation of abradable coatings for metallographic analysis, based on round robin testing by several laboratories.

Cold spray coatings technology has the potential to provide surface enhancement for applications in sectors such as defense and aerospace, oil and gas, power generation, medical, automotive, electronics, and railways. The ability to deposit clean metallic coatings is used in applications requiring corrosion/oxidation protection, erosion/wear protection, additive manufacturing, and fabricating free forms. This chapter discusses the function, advantages, and benefits of some of these applications.

This chapter discusses the effect of friction and lubrication on forgings and forging operations. The discussion covers lubrication mechanisms, the use of friction laws, tooling and process parameters, and the lubrication requirements of specific materials and forging processes. The chapter also describes several test methods for evaluating lubricants and explains how to interpret associated test data.

The Nuclear Waste Management Organization (NWMO) investigates approaches for managing Canada's used nuclear fuel. As part of a larger program investigating concepts of copper coatings, NWMO has begun exploring copper cold spray in collaboration with the National Research Council. Within the coating program, a large variety of copper coating sizes have been investigated, from small corrosion coupons to full-scale used-fuel containers/canisters (UFCs). This chapter demonstrates the successful application of copper coating technology to full-scale geometric representative Mark II UFC mock-up configurations through activities involving powder selection, general coating development, UFC coating optimization, and prototyping.

This chapter discusses the advantages and disadvantages of metal matrix composites and the methods used to produce them. It begins with a review of the composition and properties of aluminum matrix composites. It then describes discontinuous composite processing methods, including stir and slurry casting, liquid metal infiltration, spray deposition, powder metallurgy, extrusion, hot rolling, and forging. The chapter also provides information on continuous-fiber aluminum and titanium composites as well as particle-reinforced titanium and fiber metal (glass aluminum) laminates.