The cold spray process relies on the formation of atomic bonds at the particle-substrate interface, making surface engineering techniques essential for effective material build-up.

The cold spray process serves as a near-net shape additive manufacturing technique, capable of building complex geometries by using high-velocity particles that consolidate through high-strain-rate plastic deformation.

Expanding fluids can reach supersonic velocities and are commonly used to accelerate secondary micron-sized materials—such as ceramic, metal, and polymer powders—for deposition processes like cold spray. The resulting high-speed impacts generate shock waves and induce rapid changes in flow characteristics, which play a critical role in the transport, deformation, and bonding behavior of the particles upon impact with the substrate.

Cold spray is used to effectively enhance the performance and efficiency of heat exchangers. Net-shape pyramidal pin-fin arrays can be deposited using this technique, significantly improving heat transfer performance by increasing surface area and promoting turbulent flow.

Powder pre-conditioning steps are essential for effectively controlling the characteristics of the deposited coating and the in-flight behavior of particles. Chemical, thermal, and mechanical treatments are employed to fine-tune the powder’s geometry, size distribution, and material properties prior to deposition, ensuring optimal performance and consistency in the cold spray process.