Analyzing Process Variables in Cold Spray Coatings for Chemical Applications

Abstract

Cold spray (CS) coating technology has emerged as a promising method for fabricating coatings with enhanced mechanical, chemical, and thermal properties. The process involves the accelerated deposition of powder particles onto a substrate through high-velocity gas flow. Cold spray coatings are gaining significant attention in chemical industries due to their ability to create robust and durable protective layers without requiring high temperatures, thus preserving the chemical integrity of the base material. The current research focuses on understanding the influence of key process variables—such as particle velocity, nozzle design, powder feed rate, and gas pressure—on the quality and performance of cold spray coatings for chemical applications. Through a combination of experimental studies and simulation models, the relationship between these variables and coating characteristics (such as hardness, adhesion strength, and corrosion resistance) is explored. The findings contribute to optimizing cold spray process parameters, paving the way for more efficient and reliable coatings in various chemical environments.