• High strength resulting from excellent inter-particle cohesion and adhesion to the substrate.

• Very low porosity and oxide content.

• Superior corrosion and oxidation resistance.

• High thermal and electrical conductivity

Materials that can be deposited by cold spray include:

• Metals: Al, Cu, Sn, Ni, Ti, Ag, Zn, Ta, Nb, Zr, Ta.

• Alloys: steels, Ni alloys, Ti alloys, MCrAlYs.

• Composites (or blends): Cu-W, Al-SiC, Al-Al₂O₃.

The first part of the paper will summarise of the current technology position of the Cold Spray process and will include:

• An overview of the Cold Spray process equipment and related facilities

• Benchmarking with conventional thermal spray processes.

• A summary of commercial systems.

The second part of the paper will provide an overview of current Cold Spray aerospace-related application developments, including:

• Repair of Mg alloy components e.g. helicopter engine gearboxes.

• MCrAlY coatings for gas turbines.

• Copper and aluminium layers for electronic devices, heat sinks.

• Cd-plating alternatives.