Cold Spray Process Development

Developing an excellent cold spray repair is not a trivial task and can be an expensive and frustrating experience for new entrants into the cold spray world. We consider a broad range of factors, including loading levels, wear and corrosion, and accessibility. First, we examine basic feasibility, including likely materials and access issues (i.e., location sprayable?). Design data is also needed at this point to establish the properties required for the cold spray deposition. If design data is not available, we must reverse-engineer the part. Next, we select an appropriate material. If no data exists for proper material, then some initial feasibility is needed to see if reasonable properties are achievable. Finally, mock-ups or a first article are prepared and evaluated. If all tests pass, we will write a cold spray process specification for the application.

Note that cold spray allows you not only use matching materials for repairs (such as Al2024 onto Al2024). It also lets you use better materials for repair, such as a blend of stainless steel and ceramic particles on cast iron or carbon steel. The repaired area is more corrosion and wear resistant than the base material. This provides you with additional options and opportunities.