Development of cold spray from innovation to emerging future coating technology

Cold spray is one of the various names for describing an all-solid-state coating process that uses a high-speed gas jet to accelerate powder particles toward a substrate where they plastically deform and consolidate upon impact. Traditional thermal spray coating technologies require the melting or partial melting of feedstock material, and then quenching the molten droplets to produce coating. Cold spray technology belongs to the wide family of thermal spray technology and is a future of deposition of coating especially on temperature sensitive materials. In this paper the historical background of the cold spray process, fundamentals of this process and influence of the process parameters on coating properties are summarized. The main motivation for this review is to summarize the rapidly expanding common knowledge on cold spray for the researchers and engineers already or soon to be involved for their future endeavors with this new technology.