i-manager Publications

Gas Dynamic Cold Spraying: A Review on Materials, Parameters, Applications and Challenges

Santosh Kumar*, Rakesh Kumar**

*,** Department of Mechanical Engineering, Chandigarh Group of Colleges, Landran, Mohali, Punjab, India.

Periodicity:November - January'2021
DOI : https://doi.org/10.26634/jfet.16.2.17624

Abstract

Gas dynamic cold spraying is a solid state powder spraying method with several different properties such as corrosion resistance, low oxidation, high strength, high hardness, high rate of coating deposition and allowing production of coatings from a broad range of materials. This review paper aims to provide an overview of the cold spray processes, coating materials, bonding mechanism and their development in trending applications. In particular, the revolutionary applications of gas dynamic cold spray in distinct sector such as energy sector, nuclear power plant, 3D printing, biomedical, wear and dimensional restoration, antimicrobial, electrical, catalysis and corrosion protection are discussed. The current state of coating material including high melting point metal and alloy and low melting point metal and alloy (tin, aluminum, zinc, copper) are presented. In addition, the comparison of gas dynamic cold spray with distinct thermal spray coating is briefly explained as a benchmark for future research and development.

Keywords

Gas Dynamic Cold Spray, Types, Coating Materials, Comparison and Applications.

How to Cite this Article?

Kumar, S., and Kumar, R. (2021). Gas Dynamic Cold Spraying: A Review on Materials, Parameters, Applications and Challenges. i-manager's Journal on Future Engineering and Technology, 16(2), 43-56. https://doi.org/10.26634/jfet.16.2.17624

References

[1]. Ajdelsztajn, L., Zuniga, A., Jodoin, B., & Lavernia, E. J. (2006). Cold gas dynamic spraying of a high temperature Al alloy. Surface and Coatings Technology, 201(6), 2109- 2116.

[2]. Assadi, H., Kreye, H., Gärtner, F., & Klassen, T. (2016). Cold spraying: A materials perspective. Acta Materialia, 116, 382-407.https://doi.org/10.1016/j.actamat.201 6.06.034

[3]. Bala, N., Singh, H., & Prakash, S. (2009). Hightemperature oxidation studies of cold-sprayed Ni–20Cr and Ni–50Cr coatings on SAE 213-T22 boiler steel. Applied Surface Science, 255(15), 6862-6869.

[4]. Bala, N., Singh, H., & Prakash, S. (2010). Accelerated hot corrosion studies of cold spray Ni–50Cr coating on boiler steels. Materials & Design, 31(1), 244-253.

[5]. Bala, N., Singh, H., Karthikeyan, J., & Prakash, S. (2014). Cold spray coating process for corrosion protection: A review. Surface Engineering, 30, 414-421.

[6]. Bala, N., Singh, H., Prakash, S., & Karthikeyan, J. (2012). Investigations on the behavior of HVOF and cold sprayed Ni-20Cr coating on T22 boiler steel in actual boiler environment. Journal of Thermal Spray Technology, 21(1), 144-158.

[7]. Balani, K., Laha, T., Agarwal, A., Karthikeyan, J., & Munroe, N. (2005). Effect of carrier gases on microstructural and electrochemical behavior of coldsprayed 1100 aluminum coating. Surface and Coatings Technology, 195(2-3), 272-279.

[8]. Bedi, T. S., Kumar, S., & Kumar, R. (2019). Corrosion performance of hydroxyapaite and hydroxyapaite/titania bond coating for biomedical applications. Materials Research Express, 7(1), 1-17.

[9]. Bolelli, G., Bonferroni, B., Koivuluoto, H., Lusvarghi, L., & Vuoristo, P. (2010). Depth-sensing indentation for assessing the mechanical properties of cold-sprayed Ta. Surface and Coatings Technology, 205(7), 2209-2217.

[10]. Bu, H., Yandouzi, M., Lu, C., & Jodoin, B. (2011). Effect of heat treatment on the intermetallic layer of cold sprayed aluminum coatings on magnesium alloy. Surface and Coatings Technology, 205(19), 4665-4671.

[11]. Champagne, V. K., & Helfritch, D. J. (2014). Main streaming cold spray–push for applications. Surface Engineering, 30(6), 396-403.

[12]. Champagne, V., & Helfritch, D. (2015). Critical assessment 11: Structural repairs by cold spray. Materials Science and Technology, 31(6), 627-634.

[13]. Chavan, N. M., Ramakrishna, M., Phani, P. S., Rao, D. S., & Sundararajan, G. (2011). The influence of process parameters and heat treatment on the properties of cold sprayed silver coatings. Surface and Coatings Technology, 205(20), 4798-4807.

[14]. Chawla, V., Chawla, A., Sidhu, B. S., Prakash, S., & Puri, D. (2010). Oxidation behavior of nanostructured TiAlN and AlCrN thin coatings on ASTM-SA213-T-22 boiler steel. Journal of Minerals and Materials Characterization and Engineering, 9(11), 1037-1057.

[15]. Choi, H. J., Lee, M., & Lee, J. Y. (2010). Application of a cold spray technique to the fabrication of a copper canister for the geological disposal of CANDU spent fuels. Nuclear Engineering and Design, 240(10), 2714-2720.

[16]. da Silva, F. S., Cinca, N., Dosta, S., Cano, I. G., Guilemany, J. M., & Benedetti, A. V. (2017). Cold gas spray coatings: basic principles, corrosion protection and applications. Eclética Química, 42, 09-32.

[17]. Dong, H. (Ed.). (2010). Surface engineering of light alloys: Aluminium, magnesium and titanium alloys (pp. 12- 26). Elsevier.

[18]. Dosta, S., Couto, M., & Guilemany, J. M. (2013). Cold spray deposition of a WC-25Co cermet onto Al7075-T6 and carbon steel substrates. Acta Materialia, 61(2), 643-652.

[19]. Fukumoto, M., Wada, H., Tanabe, K., Yamada, M., Yamaguchi, E., Niwa, A., ...& Izawa, M. (2007). Effect of substrate temperature on deposition behavior of copper particles on substrate surfaces in the cold spray process. Journal of Thermal Spray Technology, 16(5-6), 643-650.

[20]. Gadow, R., Killinger, A., & Stiegler, N. (2010). Hydroxyapatite coatings for biomedical applications deposited by different thermal spray techniques. Surface and Coatings Technology, 205(4), 1157-1164.

[21]. Ghelichi, R., Bagherifard, S., Mac Donald, D., Brochu, M., Jahed, H., Jodoin, B., & Guagliano, M. (2014). Fatigue strength of Al alloy cold sprayed with nanocrystalline powders. International Journal of Fatigue, 65, 51-57.

[22]. Goyal, T., Walia, R. S., & Sidhu, T. S. (2012). Surface roughness optimization of cold-sprayed coatings using Taguchi method. The International Journal of Advanced Manufacturing Technology, 60(5-8), 611-623.

[23]. Huang, R., & Fukanuma, H. (2015). 6 - Future trends in cold spray techniques. Future Development of Thermal Spray Coatings, 1, 143-162.

[24]. Irissou, E., Legoux, J. G., Arsenault, B., & Moreau, C. (2007). Investigation of Al-Al O cold spray coating 2 3 formation and properties. Journal of Thermal Spray Technology, 16(5-6), 661-668.

[25]. Irissou, E., Legoux, J. G., Ryabinin, A. N., Jodoin, B., & Moreau, C. (2008). Review on cold spray process and technology: Part I - Intellectual property. Journal of Thermal Spray Technology, 17(4), 495-516.

[26]. Jodoin, B., Ajdelsztajn, L., Sansoucy, E., Zúñiga, A., Richer, P., & Lavernia, E. J. (2006). Effect of particle size, morphology, and hardness on cold gas dynamic sprayed aluminum alloy coatings. Surface and Coatings Technology, 201(6), 3422-3429.

[27]. Karthikeyan, J. (2004). Cold spray technology: International status and USA efforts [Report]. Barbeton, Ohio: ASB Industries Inc.

[28]. Karthikeyan, J. (2007). The advantages and disadvantages of the cold spray coating process. In K. C. Victor (Ed.), The Cold Spray Materials Deposition Process (pp. 62-71). Woodhead Publishing.

[29]. Kaushal, G., Bala, N., Kaur, N., Singh, H., & Prakash, S. (2014). Comparative high-temperature corrosion behavior of Ni-20Cr coatings on T22 boiler steel produced by HVOFD-Gun, and cold spraying. Metallurgical and Materials Transactions A, 45(1), 395-410.

[30]. Khun, N. W., Tan, A. W. Y., Sun, W., & Liu, E. (2017). Wear and corrosion resistance of thick Ti-6Al-4V coating deposited on Ti-6Al-4V substrate via high-pressure cold spray. Journal of Thermal Spray Technology, 26(6), 1393- 1407.

[31]. Kim, H. J., Lee, C. H., & Hwang, S. Y. (2005). Fabrication of WC–Co coatings by cold spray deposition. Surface and Coatings Technology, 191(2-3), 335-340.

[32]. King, P. C., Busch, C., Kittel-Sherri, T., Jahedi, M., & Gulizia, S. (2014). Interface melding in cold spray titanium particle impact. Surface and Coatings Technology, 239, 191–199.

[33]. Koivuluoto, H., & Vuoristo, P. (2014). Structure and corrosion properties of cold sprayed coatings: A review. Surface Engineering, 30(6), 404-413.

[34]. Kumar, M., Kant, S., & Kumar, S. (2019). Corrosion behavior of wire arc sprayed Ni-based coatings in extreme environment. Materials Research Express, 6(10).

[35]. Kumar, M., Singh, H., Singh, N., & Joshi, R. S. (2015a). Erosion–corrosion behavior of cold-spray nano-structured Ni–20Cr coatings in actual boiler environment. Wear, 332, 1035-1043.

[36]. Kumar, M., Singh, H., Singh, N., Hong, S. M., Choi, I. S., Suh, J. Y., ...& Joshi, S. V. (2015b). Development of nanocrystalline cold sprayed Ni–20Cr coatings for high temperature oxidation resistance. Surface and Coatings Technology, 266, 122-133.

[37]. Kumar, M., Singh, H., Singh, N., Chavan, N. M., Kumar, S., & Joshi, S. V. (2015c). Development of erosion-corrosionresistant cold-spray nano-structured Ni-20Cr coating for coal-fired boiler applications. Journal of Thermal Spray Technology, 24, 1441–1449.

[38]. Kumar, R., & Kumar, S. (2018). Comparative parabolic rate constant and coating properties of nickel, cobalt, iron and metal oxide based coating: A review. i-manager's Journal on Material Science, 6(1), 45-56.

[39]. Kumar, R., & Kumar, S. (2018). Thermal spray coating: A study. International Journal of Engineering Sciences & Research Technology, 7(3), 610-617.

[40]. Kumar, R., Kumar, R., & Kumar, S. (2018a). Erosion corrosion study of HVOF sprayed thermal sprayed coating on boiler tubes: A review. International Journal of Science and Management Studies, 1(3), 1-6.

[41]. Kumar, R., Singh, R., & Kumar, S. (2018b). Erosion and hot corrosion phenomena in thermal power plant and their preventive methods: A study. Asian Review of Mechanical Engineering, 7(1), 38-45.

[42]. Kumar, S., Handa, A., & Kumar, R. (2019). Overview of wire arc spray process: A review. Journal of Composition Theory, 12(7), 900-907.

[43]. Kumar, S., Kumar, M., & Handa, A. (2018). Combating hot corrosion of boiler tubes: A study. Engineering Failure Analysis, 94, 379-395.

[44]. Kumar, S., Kumar, M., & Jindal, N. (2020). Overview of cold spray coatings applications and comparisons: A critical review. World Journal of Engineering, 17(1), 27-51.

[45]. Lee, H., Shin, H., Lee, S., & Ko, K. (2008). Effect of gas pressure on Al coatings by cold gas dynamic spray. Materials Letters, 62(10-11), 1579-1581.

[46]. Levasseur, D., Yue, S., & Brochu, M. (2012). Pressure less sintering of cold sprayed Inconel 718 deposit. Materials Science and Engineering: A, 556, 343-350.

[47]. Li, W. Y., Li, C. J., Liao, H., & Coddet, C. (2007). Effect of heat treatment on the micro-structure and micro hardness of cold-sprayed tin bronze coating. Applied Surface Science, 253(14), 5967-5971.

[48]. Li, W. Y., Li, C. J., & Yang, G. J. (2010). Effect of impacti induced melting on interface micro-structure and bonding of cold-sprayed zinc coating. Applied Surface Science, 257(5), 1516-1523.

[49]. Lima, R. S., Kucuk, A., Berndt, C. C., Karthikeyan, J., Kay, C. M., & Lindemann, J. (2002). Deposition efficiency, mechanical properties and coating roughness in coldsprayed titanium. Journal of Materials Science Letters, 21(21), 1687-1689.

[50]. Meng, X., Zhang, J., Zhao, J., Liang, Y., & Zhang, Y. (2011). Influence of gas temperature on microstructure and properties of cold spray 304SS coating. Journal of Materials Science & Technology, 27(9), 809-815.

[51]. Morgan, R., Fox, P., Pattison, J., Sutcliffe, C., & O'Neill, W. (2004). Analysis of cold gas dynamically sprayed aluminium deposits. Materials Letters, 58(7-8), 1317-1320.

[52]. Moridi, A., Hassani-Gangaraj, S. M., Guagliano, M., & Dao, M. (2014). Cold spray coating: review of material systems and future perspectives. Surface Engineering, 30(6), 369-395.

[53]. Moy, C. K., Cairney, J., Ranzi, G., Jahedi, M., & Ringer, S. P. (2010). Investigating the microstructure and composition of cold gas-dynamic spray (CGDS) Ti powder deposited on Al 6063 substrate. Surface and Coatings Technology, 204(23), 3739-3749.

[54]. Oyinbo, S. T., & Jen, T. C. (2019). A comparative review on cold gas dynamic spraying processes and technologies. Manufacturing Review, 6(25), 1-20,

[55]. Page, K., Wilson, M., & Parkin, I. P. (2009). Antimicrobial surfaces and their potential in reducing the role of the inanimate environment in the incidence of hospitalacquired infections. Journal of Materials Chemistry, 19(23), 3819-3831.

[56]. Papyrin, A., Kosarev, V., Klinkov, S., Alkhimov, A., & Fomin, V. M. (2006). Cold spray technology. Elsevier.

[57]. Poza, P., Múnez, C. J., Garrido-Maneiro, M. A., Vezzù, S., Rech, S., & Trentin, A. (2014). Mechanical properties of Inconel 625 cold-sprayed coatings after laser remelting. Depth sensing indentation analysis. Surface and Coatings Technology, 243, 51-57.

[58]. Raj, S. V., Barrett, C., Karthikeyan, J., & Garlick, R. (2007). Comparison of the cyclic oxidation behavior of cold sprayed CuCrAl-coated and uncoated GRCop-84 substrates for space launch vehicles. Surface and Coatings Technology, 201(16-17), 7222-7234.

[59]. Rech, S., Surpi, A., Vezzù, S., Patelli, A., Trentin, A., Glor, J., ..., & Eklund, P. (2013). Cold-spray deposition of Ti2AlC coatings. Vacuum, 94, 69-73.

[60]. Řehořek, L., Dlouhý, I., & Jan, V. (2017). Cold gas dynamic spray deposition as additive manufacturing of architered materials. Material Engineering, 24, 115-123.

[61]. Richer, P., Yandouzi, M., Beauvais, L., & Jodoin, B. (2010). Oxidation behaviour of CoNiCrAlY bond coats produced by plasma, HVOF and cold gas dynamic spraying. Surface and Coatings Technology, 204(24), 3962-3974.

[62]. Robitaille, F., Yandouzi, M., Hind, S., & Jodoin, B. (2009). Metallic coating of aerospace carbon/epoxy composites by the pulsed gas dynamic spraying process. Surface and Coatings Technology, 203(19), 2954-2960.

[63]. Sansoucy, E., Kim, G. E., Moran, A. L., & Jodoin, B. (2007). Mechanical characteristics of Al-Co-Ce coatings produced by the cold spray process. Journal of Thermal Spray Technology, 16(5-6), 651-660.

[64]. Sharma, V., Kumar, S., Kumar, M., & Deepak, D. (2020). High temperature oxidation performance of Ni-Cr-Ti and Ni-5Al coatings. Materials Today: Proceedings, 26(3), 3397-3406.

[65]. Sidhu, H. S., & Kumar, S. (2019). Design and fabrication of prosthetic leg. A Journal of Composition Theory, 12(7), 973-981.

[66]. Sileo, G. A., Appleby, J. W., Narsavage, S. T., Alent, F. X., & Davis, C. G. (1996). U.S. Patent No. 5,536,022. Washington, DC: U.S. Patent and Trademark Office.

[67]. Singh, H., Bala, N., Kaur, N., Sharma, S. K., Kim, D. Y., & Prakash, S. (2015). Effect of additions of TiC and Re on high temperature corrosion performance of cold sprayed Ni–20Cr coatings. Surface and Coatings Technology, 280, 50-63.

[68]. Sirvent, P., Garrido, A. M., Rico, A., & Poza, A. (2019). Wear behavior of Ti-6Al-4V cold sprayed coatings under oscillating sliding tests. In IX Iberian Conference on Tribology University of Minho Portugal.

[69]. Sova, A., Grigoriev, S., Okunkova, A., & Smurov, I. (2013). Cold spray deposition of 316L stainless steel coatings on aluminium surface with following laser posttreatment. Surface and Coatings Technology, 235, 283- 289.

[70]. Sova, A., Kosarev, V. F., Papyrin, A., & Smurov, I. (2011). Effect of ceramic particle velocity on cold spray deposition of metal-ceramic coatings. Journal of Thermal Spray Technology, 20(1-2), 285-291.

[71]. Sova, A., Papyrin, A., & Smurov, I. (2009). Influence of ceramic powder size on process of cermet coating formation by cold spray. Journal of Thermal Spray Technology, 18(4), 633-641.

[72]. Spencer, K., & Zhang, M. X. (2009). Heat treatment of cold spray coatings to form protective intermetallic layers. Scripta Materialia, 61(1), 44-47.

[73]. Tao, Y., Xiong, T., Sun, C., Kong, L., Cui, X., Li, T., & Song, G. L. (2010). Microstructure and corrosion performance of a cold sprayed aluminium coating on AZ91D magnesium alloy. Corrosion Science, 52(10), 3191- 3197.

[74]. Tazegul, O., Dylmishi, V., & Cimenoglu, H. (2016). Copper matrix composite coatings produced by cold spraying process for electrical applications. Archives of Civil and Mechanical Engineering, 16(3), 344-350.

[75]. Villa, M., Dosta, S., & Guilemany, J. M. (2013). Optimization of 316L stainless steel coatings on light alloys using cold gas spray. Surface and Coatings Technology, 235, 220-225.

[76]. Vuoristo, P. (2014). Thermal spray coating processes. Comprehensive Material Processing, 4, 229-276.

[77]. Wang, F., Qi, B., Wang, G., & Cui, W. (2014). Catalyst coating deposition behavior by cold spray for fuel reforming. International Journal of Hydrogen Energy, 39(25), 13852-13858.

[78]. Wang, H. R., Li, W. Y., Ma, L., Wang, J., & Wang, Q. (2007). Corrosion behavior of cold sprayed titanium protective coating on 1Cr13 substrate in seawater. Surface and Coatings Technology, 201(9-11), 5203-5206.

[79]. Wang, J., Wang, C., & Kang, Y. (2017). The effects of annealing treatment on microstructure and contact resistance properties of cold sprayed Ag-SnO coating. 2 Journal of Alloys and Compounds, 714, 698-703.

[80]. Wang, Y. X., Yang, H., Lim, G., & Li, Y. (2010). Glass formation enhanced by oxygen in binary Zr–Cu system. Scripta Materialia, 62(9), 682-685.