Skip to main content
Log in

Evaluation of coatings produced via kinetic and cold spray processes

  • Reviewed Papers
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

An analysis of physical and mechanical properties of coatings produced by kinetic and cold spray processes is presented. Adhesion, hardnesses, porosities, critical velocities, and other properties of aluminum and copper coatings from both spray methods are analyzed and discussed, including scanning electron microscopy and optical micrographs. Similarities and differences between each of the coating methods and their effects on the resulting coatings are presented. A brief history and discussion of the bonding mechanisms for the larger particle coatings produced by the kinetic spray method is provided.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. G.H. Smith, N.Y. Kenmore, R.C. Eschenbach, and J.F. Pelton, U.S. Patent 2 861 900, Jet Plating of High Melting Point Materials (Nov. 25, 1958).

  2. C.F. Rocheville, U.S. Patent 3 100 724, Device for Treating the Surface of a Workpiece (Aug. 13, 1963).

  3. J.A. Browning: “What If We’re Right?” Thermal Spray: A United Forum for Scientific and Technological Advances, C.C. Berndt, ed., ASM International, Materials Park, OH, 1997 pp. 15–18

    Google Scholar 

  4. J.A. Browning, U.S. Patent 5 271 965, Thermal Spray Method Utilizing In-Transit Powder Particle Temperatures Below Their Melting Point (Dec. 21, 1993).

  5. A.P. Alkhimov, V.F. Kosarev, and A.N. Papyrin: “A Method of Cold Gas-Dynamic Deposition,” Dokl. Akad. Nauk SSSR, 1990, 315, pp. 1062–65.

    CAS  Google Scholar 

  6. A.P. Alkhimov, A.N. Papyrin, V.F. Kosarev, N.I. Nesterovich, and M.M. Shushpanov, U.S. Patent 5 302 414, Gas Dynamic Spraying Method for Applying a Coating (April 12, 1994).

  7. R.C. McCune, A.N. Papyrin, J.N. Hall, W.L. Riggs II, and P.H. Zajchowski: “An Exploration of the Cold Gas Dynamic Spray Method for Several Material Systems” in Thermal Spray Science & Technology, C.C. Berndt and S. Sampath ed., ASM International, Materials Park, OH, 1995, pp. 1–5.

    Google Scholar 

  8. R.C. Dykhuizen, M.F. Smith, D.L. Gilmore, R.A. Neiser, X. Jiang, and S. Sampath: “Impact of High Velocity Cold Spray Particles,” J. Therm. Spray Technol., 1998, 8, pp. 559–64.

    Article  Google Scholar 

  9. R.C. Dykhuizen and M.F. Smith: “Gas Dynamic Principles of Cold Spray,” J. Therm. Spray Technol. 1998, 7(2), pp. 205–12.

    Article  CAS  Google Scholar 

  10. D.L. Gilmore, R.C. Dykhuizan, R.A. Neiser, T.J. Roemer, and M.F. Smith: “Particle Velocity and Deposition Efficiency in the Cold Spray Process,” J. Therm. Spray Technol, 1999, 8(4), pp. 576–82.

    Article  CAS  Google Scholar 

  11. M.F. Smith, J.E. Brockmann, R.C. Dykhuizen, D.L. Gilmore, R.A. Neiser, and T.J. Roemer: “Cold Spray Direct Fabrication-High Rate, Solid State, Material Consolidation” in Solid Freeform and Additive Fabrication, D. Dimos, S.C. Danforth, and M.J. Cima, ed., MRS Symposia Proceedings Vol. 542, Materials Research Society, Warrendale, PA, 1998, pp. 65–67.

    Google Scholar 

  12. A.P. Alkhimov, V.F. Kosarev, and A.N. Papyrin: “Gas-Dynamic Spraying, Study of Plane Supersonic Two Phase Jet,” J. Appl. Mech. Tech. Phys., 1997, 38(2), pp. 176–83.

    Google Scholar 

  13. A.P. Alkhimov, V.F. Kosarev, and A.N. Papyrin: “Gas-Dynamic Spraying, Experimental Study of the Spray Process,” J. Appl. Mech. Tech. Phys., 1997, 38(2), pp. 183–88.

    Google Scholar 

  14. A.P. Alkhimov, V.F. Kosarev, and A.N. Papyrin: “Spraying Current Conducting Coatings On Electro-Technical Units by CGS Methods” in Tagungsband Conference Proceedings, E. Lugscheider and R.A. Kammer, ed., DVS Deutscher Verband fur Schweiben, Dusseldorf, Germany, 1999, pp. 288–90.

    Google Scholar 

  15. A.P. Alkhimov, A.I. Gulidov, V.F. Kosarev, and N.I. Nesterovich: “Specific Features of Microparticle Deformation Upon Impact on a Rigid Barrier,” J. Appl. Mech. Tech. Physics, 2000, 41(1) pp. 204–209.

    Google Scholar 

  16. A.P. Alkhimov, S.V. Klinkov, and V.F. Kosarev: “Impingement of a Supersonic Jet of a Rectangular Cut On A Flat Barrier,” Thermophys. Aeromech., 2000, 7(2), pp. 221–28.

    Google Scholar 

  17. A.P. Alkhimov, S.V. Klinkov, and V.F. Kosarev: “Study of Heat Exchange of a Supersonic Plane Jet with Obstacle at Gas-Dynamic Spraying,” Thermophys. Aeromech., 2000, 7(3), pp. 375–82.

    Google Scholar 

  18. R.B. Bhagat, M.F. Amateau, A.N. Papyrin, J.C. Conway, Jr., B. Strutzman, and B. Jones: “Deposition of Nickel-Aluminum Bronze Powder by Cold Gas-Dynamic Spray Method on 2618 Al for Developing Wear Resistant Coatings” in Thermal Spray: A United Forum for Scientific and Technological Advances, C.C. Berndt, ed., ASM International, Materials Park, OH, 1997, pp 361–67.

    Google Scholar 

  19. A.E. Segall, A. Nyrin, J.C. Conway, Jr., and D. Shapiro: “A Cold-Gas Spray Coating Process for Enhancing Titanium,” JOM, 1998, 50(9), pp. 52–54.

    Article  CAS  Google Scholar 

  20. H. Kreye and T. Stoltenhoff: “Cold Spray-Study of Process and Coating Characteristics” in Thermal Spray: Surface Engineering via Applied Research, C.C. Berndt, ed., ASM International, Materials Park, OH, 2000, p. 419.

    Google Scholar 

  21. B. Jodoin: Effects of Shock Waves on Impact Velocity of Cold Spray Particles, pp. 399- Thermal Spray 2001: New Surfaces for a New Millennium. C.C. Berndt Ed., K.A. Khor, and E.F. Lugscheider (Eds.), Pub. ASM International, Materials Park, OH-USA, 2001, p. 399.

    Google Scholar 

  22. J. Karthikeyan, A. Kay, J. Lindeman, R.S. Lima, and C.C. Berndt: “Cold Spray Processing of Titanium Powder,” Thermal Spray: Surface Engineering via Applied Research, C.C. Berndt, ed., ASM International, Materials Park, OH, 2000, pp. 255–62.

    Google Scholar 

  23. T.H. Van Steenkiste, J.R. Smith, R.E. Teets, J.J. Moleski, and D.W. Gorkiewicz, U.S. Patent 6 139 913. Kinetic Spray Coating Method and Apparatus (Oct. 31, 2000)

  24. T.H. Van Steenkiste, J.R. Smith, R.E. Teets, J.J. Moleski, and D.W. Gorkiewicz, U.S. Patent 6 283 386B1. Kinetic Spray Coating Apparatus (Sept. 4, 2001).

  25. T.H. Van Steenkiste, J.R. Smith, and R.E. Teets: “Aluminum Coatings Via Kinetic Spray with Relatively Large Powder Particles,” Surf. Coat. Technol., 2002, 154, pp. 237–52.

    Article  Google Scholar 

  26. T.H. Van Steenkiste, J.R. Smith, R.E. Teets, J.J. Moleski, D.W. Gorkiewicz, R.P. Tison, D.R. Marantz, K.A. Kowalsky, W.L. Riggs II, P.H. Zajchowski, B. Pilsner, R.C. McCune, and K.J. Barnett: “Kinetic Spray Coatings,” Surf. Coat. Technol., 1999, 111, pp. 62–71.

    Article  Google Scholar 

  27. M. Jacobson, A.R. Cooper, and J. Nagy: “Explosibility of Metal Powders,” U.S. Bureau of Mines, Washington, DC, RI 5624, 1960.

    Google Scholar 

  28. T.H. Van Steenkiste: “Kinetic Spray: A New Coating Process,” Durable Surf., Key Eng. Mater., 2001, 197, Trans Tech Publications, Switzerland, pp. 59–86.

    Google Scholar 

  29. J.D. Anderson, Jr., Modern Compressible Flow, McGraw-Hill, New York, 1982.

    Google Scholar 

  30. C.B. Henderson: “Drag Coefficients of Spheres in Continuum and Rarefied Flows,” AIAA J., 1976, 14, pp. 707–21.

    Google Scholar 

  31. D.J. Carlson and R.F. Hoglund: “Particle Drag and Heat Transfer in Rocket Nozzles,” AIAA J., 1964, 2, pp. 1980–84.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Rights and permissions

Reprints and permissions

About this article

Cite this article

Van Steenkiste, T., Smith, J.R. Evaluation of coatings produced via kinetic and cold spray processes. J Therm Spray Tech 13, 274–282 (2004). https://doi.org/10.1361/10599630419427

Download citation

  • Received:

  • Revised:

  • Issue Date:

  • DOI: https://doi.org/10.1361/10599630419427

Keywords

Navigation