Abstract: A method comprising: cold-spraying a surface of a substrate with a bond material to form a bond coating; and cold-spraying a surface of the bond coating with a coating material to form a top coating. The bond material is different from the coating material and harder than the surface of the substrate.

Abstract: A method of joining first and second component bodies comprises: cold-spraying a first joining surface of the first component body with a bond material which is harder than the first joining surface; cold-spraying a second joining surface of the second component body with the bond material; and joining the first and second component bodies by way of the first joining surface.

Abstract: A Cold spray nozzle assembly for depositing powder material onto a component surface includes a primary spray nozzle, two or more secondary spray nozzles, and a support mechanism supporting each spray nozzle. Each spray nozzle deposits powder material on a single target point on the surface, a reference plane being defined normal to a surface plane at the target point. The primary nozzle is in a primary plane that is normal to the surface plane, and that defines a primary dihedral angle with the reference plane. An axis of the primary nozzle defines a primary nozzle angle with the surface plane. Each of the secondary spray nozzles is in a corresponding secondary plane, with each being normal to the surface plane and defining a respective secondary dihedral-angle with the reference plane. An axis of each secondary spray nozzle defines a respective secondary nozzle angle with the surface plane.

Abstract: Cold spray nozzle assembly for depositing powder material onto a surface of a component includes a primary spray nozzle, two or more secondary spray nozzles, and nozzle support mechanism that supports each spray nozzle. Each spray nozzle deposits powder material on a single target point on the surface, a reference-plane being defined normal to a surface-plane at the target point. The primary nozzle is in a primary-plane, the primary-plane being normal to the surface-plane, and defining a primary dihedral-angle with the reference-plane. An axis of the primary nozzle defines a primary nozzle-angle with the surface-plane. Each of the two or more secondary spray nozzles is in a corresponding secondary-plane, with each of the two or more secondary-planes being normal to the surface-plane, defining a respective secondary dihedral-angle with the reference-plane. An axis of each of the two or more secondary spray nozzles defines a respective secondary nozzle-angle with the surface-plane.