Study of low-pressure cold spray additive manufacturing: Influence of kinematic spray parameters on coating distribution and properties

Based on the portability of the equipment, low-pressure cold spray (LPCS) broadens the application field for cold spray. When the LPCS is applied on the additive manufacturing (LPCSAM) fields, the determination of the following parameters will have a significant implication: the temperature and pressure of the gas, Stand-off distance (SOD), gun traverse speed and the number of the passes of the gun. This work aims to determine the optimal parameters of the LPCSAM by exploring the influence of these parameters on coating distribution and properties. The Cu-Al2O3 powder is sprayed on the aluminum substrate through LPCS. The coating thickness, deposition rate and porosity under different coating conditions have been studied. It has been observed that the best spraying effect with high deposition efficiency (DE) and without clogging the gun is obtained with the nitrogen pressure of 0.9 MPa and the temperature of 400℃. The DE is respectively related to SOD, gun traverse speed and the number of scanning.