Abstract: Various embodiments disclosed relate to a method of cold-spray deposition involving cooling the cold-spray nozzle by at least one of expanding and vaporizing a compressed cooling fluid in proximity to the cold-spray nozzle. The present disclosure also includes a cold-spray deposition spray head, a cooling jacket for a cold-spray deposition nozzle and a cold-spray deposition system comprising the same.

Abstract: Various embodiments disclosed relate to a method of cold-spray deposition involving cooling the cold-spray nozzle by at least one of expanding and vaporizing a compressed cooling fluid in proximity to the cold-spray nozzle. The present disclosure also includes a cold-spray deposition spray head, a cooling jacket for a cold-spray deposition nozzle and a cold-spray deposition system comprising the same.

Abstract: A process for joining dissimilar materials. The process includes providing a first component made from a first material and a second component made from a second material. The process also includes cold spraying a bead of the second material onto the first component and joining the second component to the bead on the first component such that a weldment is formed from the first component and the second component. In some instances, joining of the second component to the bead on the first component is performed by fusion welding the bead and the second component together.

Abstract: A wear resistant coating protects against corrosion and erosion of the thin metal protective sheath on turbomachinery applications. The coating has a metal layer overlaid by a ceramic layer. Multiple metal and ceramic layers can make up the coating with the layers varying in thickness allowing the layers nearer the substrate to remain more malleable to bend with the sheath and those layers nearer the top of the coating to be more brittle and resistant to wear. A cold spray metallic layer applied to the substrate provides a lightweight, flexible layer beneath the corrosion and erosion resistant protective multilayer coating.

Abstract: A cold spray nozzle assembly is disclosed that includes a nozzle body formed from a first material and an adapter body formed from a second material wherein each body has a passage the communicates with one another along an axis. The nozzle body is formed from a polymeric material and the adapter body formed from a metallic material.

Abstract: A process for joining dissimilar materials. The process includes providing a first component made from a first material and a second component made from a second material. The process also includes cold spraying a bead of the second material onto the first component and joining the second component to the bead on the first component such that a weldment is formed from the first component and the second component. In some instances, joining of the second component to the bead on the first component is performed by fusion welding the bead and the second component together.

Abstract: A method for making parts in conjunction with a mold having a negative shape of the part. The mold is coated with a release agent and thereafter the part material is deposited on the release agent in the mold by gas dynamic cold spray. Thereafter, the release agent is separated from both the mold and the part either thermally, chemically, or mechanically.

Abstract: A cold spray apparatus is provided that includes a nozzle having a converging section and a diverging terminal section. A gas supply meters a majority by atomic percent helium gas to the nozzle at an incident gas temperature of less than 30° Celsius and at an incident velocity of between 2 and 6 MPa. A particulate feeder provides ductile material particulate having a mean x-y-z axially averaged linear dimension of between 0.9 and 95 microns to the nozzle. A composition is also provided that includes a substrate and a coating of ductile metal. The coating has a void density of less than 1% by volume, and an average domain size of between 0.9 and 95 microns. The coating has a compressive residual stress.