Processing parameters affecting cold spay coatings performances

In the present paper, the microstructural and mechanical properties of metal–metal cold spray deposits are described. Different spray particles coatings (Al-, Ti-, Ni-based particles) deposited on different substrates (Al-, Ti-, Fe-, Ni-, Mg-based bulk materials) were produced and their mechanical and microstructural properties were characterized. Microhardness, porosity, grain size and adhesion strength of the coatings were analyzed as a function of processing parameters such as particle velocity, particle dimensions, gas density, substrate hardness, and temperature. The results were employed to build a database used to obtain a provisional model through a multi-objective optimization software. For each different substrate and particle type, the working points were defined in terms of processing parameters to optimize mechanical and microstructural behavior of coatings. The error calculation of the final properties of the deposits demonstrated the precision of the developed model.