Cold spray material deposition differs significantly from other thermal spray systems in that the cold spray process does not melt particles, particle velocities are very high, and the gas/particle jet plume has a relatively low temperature. Cold spray can thus be applied to applications with heat-sensitive substrates or those applications that do not allow heat-modified deposits. The impact consolidation of high velocity, solid state, particles yield cold spray depositions with high strength, low porosity and minimal or compressive residual stress. This review will be useful to individuals new to cold spray, as well as to the cold spraying community and to product developers needing cold spray capability. The applications presented here can demonstrate capabilities that are of use to new and related uses. The descriptions of the equipment and techniques used to create the cold-sprayed deposits will be helpful to those individuals and firms seeking to produce products requiring similar characteristics.
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