A systematic approach to material eligibility for the cold-spray process

This article represents an effort to systematize an understanding of the cold-spray process and the suitability of materials for such a process. The evaluation is based on a brief analysis of the powder particle impact and literature research concerning shock-compression phenomena in matter and related physical effects, such as impact heating and dynamic yielding. The finite-element modeling (FEM) allows the estimation of the maximum impact pressures, the deformation rates, and the deformation kinetics during impact. The calculations can be verified experimentally and are supported by the published data. From a brief analysis of the equations of state applied to shock compression, key material parameters are derived and investigated. A parameterization of physical properties and correlation with the crystal types endeavors to provide a qualitative ranking of material suitability.