A Review of Advances in Cold Spray Coating Process

Authors

  • Saikumar Chalivendra Independent Researcher, USA Author

DOI:

https://doi.org/10.32628/IJSRMME

Keywords:

Spray Coating, Thermal, Gun, Helium

Abstract

Cold spray coating technique gives rise to a new technique of applying high performance coatings to different substrates. Not the same as more typical thermal spraying methods which ionize materials and melt them before spraying them at the surface of the substrate at several hundred degrees, it involves the use of a high-pressure gas to propel powdered material towards a surface at supersonic velocities and create robust and firm mechanical bonds that do not require the application of heat. This process has drastically developed to the extent of material choice, quality coatings, and commercial uses. However, there are still some problems which have to be solved, namely the preparation of the substrate, the choice of the material and the cost of equipment. This paper examines the most recent innovations in the cold spray technique, its uses, advantages and limitations, and the future prospects of this pioneering coating method.

References

Aparco, R. H., Tapia-Tadeo, F., Ascarza, Y. B., Ramírez, A. L., Huamán-Romaní, Y. L., & Otero, C. C. (2024). A Machine Learning Approach for Analyzing Residual Stress Distribution in Cold Spray Coatings. Journal of Thermal Spray Technology, 1-16. https://doi.org/10.1007/s11666-024-01776-6

Ashokkumar, M., Thirumalaikumarasamy, D., Sonar, T., Ivanov, M., Deepak, S., Rajangam, P., & Barathiraja, R. (2023). Effect of post-processing treatments on mechanical performance of cold spray coating–an overview. Journal of the Mechanical Behavior of Materials, 32(1), 20220271. https://www.degruyter.com/document/doi/10.1515/jmbm-2022-0271/html

Ashokkumar, M., Thirumalaikumarasamy, D., Sonar, T., Vignesh, P., & Deepak, S. (2023). Optimization of cold spray coating parameters using RSM for reducing the porosity level of AA2024/Al2O3 coating on AZ31B magnesium alloy. International Journal on Interactive Design and Manufacturing (IJIDeM), 1-15. https://doi.org/10.1007/s12008-023-01597-x

Dai, S., Cui, M., Li, J., & Zhang, M. (2024). Cold Spray Technology and Its Application in the Manufacturing of Metal Matrix Composite Materials with Carbon-Based Reinforcements. Coatings, 14(7), 822. https://doi.org/10.3390/coatings14070822

Dayı, S. C., & Kılıçay, K. (2024). Repairing Al7075 surface using cold spray technology with different metal/ceramic powders. Surface and Coatings Technology, 489, 131124. https://doi.org/10.1016/j.surfcoat.2024.131124

Devi, G. N., Kumar, S., Mangalarapu, T. B., Vinay, G., Chavan, N. M., & Gopal, A. V. (2023). Assessing critical process condition for bonding in cold spraying. Surface and Coatings Technology, 470, 129839. https://doi.org/10.1016/j.surfcoat.2023.129839

Gaur, U. P., & Kamari, E. (2024). Applications of Thermal Spray Coatings: A Review. J. Therm. Spray Eng, 4, 106-114. https://doi.org/10.52687/2582-1474/405

Henao, J., Giraldo-Betancur, A., Poblano-Salas, C. A., Espinosa-Arbelaez, D. G., Corona-Castuera, J., Forero-Sossa, P. A., & Diaz-Rebollar, R. (2024). On the Role of Substrate in Hydroxyapatite Coating Formation by Cold Spray. Coatings, 14(10), 1302. https://doi.org/10.3390/coatings14101302

Khatake, P., Taluja, R., Kumar, M. S., Reddy, M. M., Al-Ataby, F. H., Sood, S., & Sonia, P. (2023). Cold spray coating: A review of material systems and future perspectives. Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2023.11.015

Mehta, A., Vasudev, H., & Thakur, L. (2024). Application of cold spray technology in design and manufacturing of complex geometries. International Journal on Interactive Design and Manufacturing (IJIDeM), 1-19. https://doi.org/10.1007/s12008-024-01826-x

Mohankumar, A., Thirumalaikumarasamy, D., Sonar, T., Ivanov, M., Vignesh, P., Pavendhan, R., ... & Xu, J. (2024). Cold spray processing of AA2024/Al2O3 coating on magnesium AZ31B alloy: Process parameters optimization, microstructure and adhesive strength performance of coating. International Journal of Lightweight Materials and Manufacture. https://doi.org/10.1016/j.ijlmm.2024.05.002

Sandhu, H. S., Goyal, D., Sharma, A., Goyal, T., Jarial, S., & Sharda, A. (2023). Sustainable development in cold gas dynamic spray coating process for biomedical applications: Challenges and future perspective review. International Journal on Interactive Design and Manufacturing (IJIDeM), 1-17. https://doi.org/10.1007/s12008-023-01474-7

Sharma, D., Boruah, D., Ameen, A., Bakir, A. A., & Paul, S. (2024). Optimizing Cold Spray Parameters for High Entropy Alloy Coatings Using Taguchi and Box–Behnken Design Approaches for Mechanically Alloyed Powder. Journal of Thermal Spray Technology, 1-20. https://doi.org/10.1007/s11666-024-01838-9

Singh, H., Kumar, M., & Singh, R. (2023). Development of high-pressure cold spray coatings of tungsten carbide composites. Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2022.12.210

Tao, H., Cai, Q., Chen, M., Zhang, W., Cao, G., & Zhang, H. (2024). Effect of heat treatment on the microstructure and corrosion performance of 2219 Al alloy cold sprayed coatings. Corrosion Science, 241, 112526. https://doi.org/10.1016/j.corsci.2024.112526

Torres, F., & Fernandez, R. (2024). Effect of Thickness on the Residual Stress Profile of an Aluminum Cold Spray Coating by Finite Element Analysis. Coatings, 14(6), 665. https://doi.org/10.3390/coatings14060665

Downloads

Published

30-03-2024

Issue

Section

Research Articles

How to Cite

A Review of Advances in Cold Spray Coating Process. (2024). International Journal of Scientific Research in Mechanical and Materials Engineering, 8(2), 53-62. https://doi.org/10.32628/IJSRMME

Similar Articles

You may also start an advanced similarity search for this article.