Development of Cold Spray and the Current Research Status at Home and Abroad

The concept of cold spraying was proposed in 1990, originating from experiments conducted in the mid-1980s at a Soviet research institute. During supersonic wind-tunnel tests using tracer particles, researchers observed that when the particle velocity exceeded a certain critical threshold, the interaction between the tracer particles and the target surface shifted from erosion to accelerated deposition.

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Coating spray equipment

Cold spray equipment

Aerospace field

Thermal Barrier Coating

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Development of Cold Spray and Current Research Status at Home and Abroad

The concept of cold spraying was introduced in... 1990 Proposed in the year, its origin lies in... 80 In the mid-1980s, during supersonic wind-tunnel tests using tracer particles at the former Soviet Union’s Institute, it was discovered that when the particle velocity exceeded a certain critical value, the effect of the tracer particles on the target surface shifted from erosion to accelerated deposition. 1995 The original Soviet researchers who first participated in cold spray research. Papyrin Presented the findings of a joint study with U.S. scholars at the National Thermal Spray Conference held in the United States. 2000 In the year [year not specified], a discussion session on cold spray technology was organized at the Thermal Spray Conference held in Canada, thereby drawing widespread attention to this technology. In recent years, major universities and research institutions around the world—including those in the United States, Germany, the United Kingdom, Japan, and China—have conducted extensive research on cold spray technology. The specifics are as follows:

1 Russia

1990 In the year, the Institute of Theoretical and Applied Mechanics of the Siberian Branch of the Russian Academy of Sciences proposed... “ Cold spraying ” Conceptually, researchers subsequently conducted in-depth studies on the theory and structure of cold spray technology—for instance, meticulously examining the acceleration and damping of supersonic two-phase gas flows, developing mathematical formulas, and analyzing particle ejection velocities under various pressure, temperature, and driving-gas conditions. They also established statistical models for the cold-spray process, investigated the influence of the thermal capacity of the gas flow and obstacles on the process, and quantified the deformation of particles upon impact with obstacles, thereby identifying optimal conditions for spray technology. Furthermore, they explored specific design schemes for the application of cold-spray technology, striving to use air as the driving gas. These studies have laid a solid foundation for the development of cold-spray equipment.

Russian Oberniske powder coating, in Au · Fee · Under Klyuyev’s leadership, the implementation method of gas-dynamic spraying technology was transformed. They proposed using only... 10 Air pressure below atmospheric pressure enables gas-dynamic spraying technology for mixing pure metals with metal particles and ceramic powders. In the accelerated airflow, ceramic particles are simultaneously introduced to supplement the kinetic energy of the metal particles, which may be insufficient on their own. The accelerated ceramic particles interact with the substrate, dynamically processing the resulting coating. This process yields dense, uniform, and ductile metal coatings—such as aluminum, copper, zinc, and nickel. This dynamic metallization process is referred to as: ” Ju Meite ” ( Dymet ) Technology.

“ Ju Meite ” The technology employs air spraying, with a gas consumption of: 0.5 cubic meter / Points, pressure is 5–8 Atmospheric pressure. The efficiency of metal particle deposition is lower than that of other methods, at approximately... 50% This is because the ceramic particles added to the biphasic mixture are essentially bounced back by the matrix. The overall deposition efficiency is approximately... 20-30% Due to the low gas consumption, the overall production efficiency is also limited by the consumption of powder materials, namely... 0.5–0.6 Ker / Second 。

“ Ju Meite ” Schematic diagram of the technical principle

2 Ukraine

In Ukraine, researchers have been studying gas-dynamic spraying technology. They use air (heated) 250 Celsius, with a pressure of 18 Atmospheric pressure, used as the driving gas, determines that the spray size is greater than 50 The potential application of micrometer-sized particles arises because, as the supersonic airflow undergoes adiabatic cooling, they gradually cool down in the nozzle’s expanding section.

3 , United States

Research on American cold spray technology began with... 90 Mid-19th century, by Babylion and the United States Sandia National Laboratories The laboratories jointly began their research and designed the basic apparatus for gas-dynamic spraying. Ktech The company produces gas-powered spray equipment for industrial computer systems, with air pressures reaching... 30 Atmospheric pressure, power is 25 Kilowatt. ASB The industrial company has improved the operational performance of its cold-spray equipment. A key issue with the equipment is that, when a strongly heated biphasic mixture is used, metal particles tend to deposit severely at the critical cross-section of the nozzle. The study also examined particle size... 50-150 Spraying technology for micrometer-sized particles. The U.S. Defense Research Laboratory and the University of Pennsylvania have also conducted research on optimizing spraying technologies, focusing on improving the characteristics of drive nozzles, selecting optimal spray powder materials, and studying and identifying the properties of the resulting coatings as well as their applications in various technical tasks.

4 , United Kingdom

In the UK, research on cold spray technology is being conducted at the University of Cambridge, the University of Liverpool, and the University of Nottingham. The primary research focus is on investigating the properties of coatings obtained using pure helium-based cold spray technology and exploring the possibility of directly manufacturing parts with specific shapes using cold spray technology.

5 Canada

Canadian Materials Research Institute ( CNRC NRC The low-temperature spraying technology of ) can achieve 200℃ Spraying at the following temperatures, coating thickness: ≥4mm The technology injects particles at a velocity of... 1200 Rice / Second, the hardness of the coating can be controlled by the hardness of the metal particle raw materials. According to... NRC It was reported that some of its particle suppliers are from China. This technology allows for spraying on both the inner and outer surfaces of parts; when spraying the interior of hollow components, the inner diameter should... ≥70mm Before spraying, the surface of the parts must be treated with aluminum sand. For this technology, both the spraying equipment and raw materials can be directly procured; the key challenge lies in the research on the spraying process itself. NRC They don’t manufacture equipment themselves; instead, they primarily focus on researching the specific process requirements for coating different raw materials and various part materials.

The University of Ottawa in Canada has employed pure helium and nitrogen as jet gases to conduct extensive research on cold spray technology and coating properties, primarily focusing on improving particle propulsion techniques within the nozzle and exploring the potential for applications across various processing procedures.

6 , Japan

The Japanese Shunshuku University is conducting research on optimizing nozzles. They have discovered that the length of nozzles designed to propel heavy particles can be significantly increased. Furthermore, after the critical section, they adopt a vertical feeding method for metal particles, which effectively prevents particle deposition at the critical section when using highly preheated gases and also shortens the acceleration length.

7 Germany

The University of Bielefeld in Hamburg, Germany, is also conducting extensive research on cold spray technology. Based on mathematical simulations and experimental studies, German researchers have developed a detailed model of cold spray technology and identified the standard conditions for particle solidification on coatings. They found that when particles impact a barrier, exceeding a critical velocity triggers an adiabatic instability, leading to plastic deformation of the particles and their subsequent fixation onto the barrier. Building on these findings, they have determined the critical velocity values for various metal particles and have designed optimized round-nozzle nozzles specifically for cold spray applications. CGT Based on the aforementioned research, the company has developed gas-powered spray equipment with a power output of: 30 Kilowatts. To achieve deposition and high-quality coatings, the equipment uses helium as the working gas.

8 China

Many universities and research institutes in China have conducted research on cold spray technology, including primarily Xi'an Jiaotong University, the Institute of Metal Research of the Chinese Academy of Sciences, the Harbin Welding Research Institute, Dalian University of Technology, Northwestern Polytechnical University, Shanghai Jiao Tong University, Beijing University of Technology, Jimei University, Ningbo Academy of Military Science, the Ningbo Institute of Materials of the Chinese Academy of Sciences, Zhejiang University of Technology, and Beijing University of Science and Technology.

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