Review of Relationship Between Particle Deformation, Coating Microstructure, and Properties in High-Pressure Cold Spray

• Published in: Journal of thermal spray technology Vol. 26; no. 6; pp. 1308 - 1355
• Main Authors: Rokni, M. R., Nutt, S. R., Widener, C. A., Champagne, V. K., Hrabe, R. H.
• Format: Journal Article
• Language: English
• Published: New York Springer US 01-08-2017
• Subjects: Analytical Chemistry; Characterization and Evaluation of Materials; Chemistry and Materials Science; Corrosion and Coatings; Machines; Manufacturing; Materials Science; Processes; Review; Surfaces and Interfaces; Thin Films; Tribology; high-pressure cold spray; cold spray; microstructure evolution; particle deformation; mechanical properties
• ISSN: 1059-9630; 1544-1016
• DOI: 10.1007/s11666-017-0575-0

In the cold spray (CS) process, deposits are produced by depositing powder particles at high velocity onto a substrate. Powders deposited by CS do not undergo melting before or upon impacting the substrate. This feature makes CS suitable for deposition of a wide variety of materials, most commonly metallic alloys, but also ceramics and composites. During processing, the particles undergo severe plastic deformation and create a more mechanical and less metallurgical bond with the underlying material. The deformation behavior of an individual particle depends on multiple material and process parameters that are classified into three major groups—powder characteristics, geometric parameters, and processing parameters, each with their own subcategories. Changing any of these parameters leads to evolution of a different microstructure and consequently changes the mechanical properties in the deposit. While cold spray technology has matured during the last decade, the process is inherently complex, and thus, the effects of deposition parameters on particle deformation, deposit microstructure, and mechanical properties remain unclear. The purpose of this paper is to review the parameters that have been investigated up to now with an emphasis on the existent relationships between particle deformation behavior, microstructure, and mechanical properties of various cold spray deposits.