Addressing challenges in deposition efficiency and material compatibility in low-pressure cold spray systems

Abstract

Low Pressure Cold Spray (LPCS) has emerged as a promising solid-state material deposition technology, offering unique advantages such as minimal thermal impact, preservation of substrate integrity, and the ability to restore or manufacture components across various industries including aerospace, electronics, and civil infrastructure. By operating at relatively low temperatures, LPCS minimizes oxidation and residual stress, enabling the deposition of heat-sensitive and high-reflectivity materials. Despite these benefits, LPCS faces critical challenges, particularly in achieving high deposition efficiency, ensuring compatibility with brittle and soft substrates, and maintaining operational stability in diverse environments. This study provides a comprehensive review of the key parameters influencing LPCS performance, including gas pressure, gas temperature, nozzle geometry, stand-off distance, and powder feeding systems. An experimental framework is synthesized to highlight effective strategies for enhancing particle velocity, reducing porosity, and improving coating adhesion. Furthermore, the paper discusses emerging innovations such as advanced nozzle designs, adaptive compressor systems, sustainable carrier gas alternatives, and real-time process monitoring. Significantly, machine learning-based predictive models are identified as a transformative approach to optimize LPCS operations, enabling real-time control and reducing dependence on traditional trial-and-error experimentation. These models offer the potential for autonomous adjustment of process parameters, leading to consistently higher deposition quality and greater operational efficiency. By integrating experimental advancements with intelligent control strategies, LPCS technology is poised to achieve broader industrial adoption, contributing to sustainable manufacturing and remanufacturing practices. This work consolidates current developments and identifies future directions to unlock the full potential of LPCS systems.