A comparative review on cold gas dynamic spraying processes and technologies

Open Access

Review

Table 3

Details of process parameters.

Particle	Substrate	Propellant gas	Particle diameter (μm)	Temperature (°C)	Pressure (MPa)	Nozzle throat diameter (mm)	Nozzle length (mm)	Ref.
Ag	SS347_{(grit blasted)}	Air	15–50	250–450	1–2	–	–	[92]
Al	Al_(pickled)	He	20	20	1.5–2	–	–	[93]
Al	Al	–	2–20	–	–	–	–	[94]
Al	Al2024 T351_{(grit blasted)}	N₂	5–50	230	3.45	2	168	[95]
Al1100	Al1100	He + N₂	1–30	227–527	2.1	–	–	[96]
Al2618	Al_{(grit blasted)}	He	<25	20	1.7	–	–	[97]
Al2618	Al6061_{(grit blasted)}	He	25–38	20	1.4	–	–	[98]
Al7075	Al5052_{(grit blasted)}	N₂	–	500	1.6	2	–	[99]
Al	AZ91 Mg	He	15	200	0.62	–	–	[100]
Al	AZ91D_{(sand blasted)}	Air	1–40	230	1.6	2 × 4	–	[101]
Al101	AZ91D_{(grit blasted)}	He	6–174	300	0.98	–	–	[102]
Al	Brass_{(sand blasted)}	Air	40; 60; 80	204–371	2	3	80	[103]
Al	Ni	Air	∼80	280	0.7–2.5	1	–	[104]
Al	Sn	He	15–75	20	2.5	–	–	[47]
Al	Cu	✓	✓	✓	✓	–	–	[47]
Al	Al6063	✓	✓	✓	✓	–	–	[47]
Al	Brass	✓	✓	✓	✓	–	–	[47]
Al	Bs B01	✓	✓	✓	✓	–	–	[47]
Al	SS1040	✓	✓	✓	✓	–	–	[47]
Al	Al₂O₃	✓	✓	✓	✓	–	–	[47]
Cu	Al6061_(polished)	N₂	–	300	1.5	–	–	[82]
Cu	Al6082_(polished)	He	5–25	20	3	1.35		[105]
Cu	Cu_{(grit blasted)}	Air	75	500	2.5	–	–	[106]
Cu	Cu_{(grit blasted)}	He	1.32	–	–	–	–	[107]
Cu	Cast iron	N₂	1–50	600	2.7	–	–	[108]
Cu	SS400_{(grit blasted, polished)}	Air	5–50	300	3	2	50	[109]
Cu	SS AlSI304_(polished)	Air	5; 10; 15	250–650	0.4–1	2	130	[110]
Cu	Al6063_(polished)	Air	5; 10; 15	250–650	0.4–1	2	130	[110]
Cu	SS AISI 304 _{(4000C-Polished)}	He	5; 15	20; 400	0.2–1	2	130	[110]
Inconel 625	SS 304_{(grit blasted)}	N₂	38–15	500	3.2–3.3	–	–	[111]
Inconel 718	Mild steel_{(grit blasted)}	N₂	33	800	3.5	–	–	[112]
Ni	Steel_{(grit blasted)}	N₂	5–22	600	3	–	–	[32]
SS 304	Steel_{(Interstitial free)}	N₂	52	450–550	3	–	–	[113]
SS 316L	Al	N₂	18–25	500	4	–	–	[114]
SS 316L	Al	N₂	28–45	600	4	–	–	[114]
SS 316L	Al	N₂	36–53	720	4	–	–	[114]
SS 316L	Al7075 T6_(pickled)	N₂	20–40	600–800	2–4	–	–	[115]
Ta	Al_(cleaned)	N₂	10–30	800	3.8	–	–	[116]
Ta	Steel_{(grit blasted)}	N₂	10–30	800	3.8	–	–	[116]
Ti	Al_{(grit blasted)}	N₂	–	370–480	2.7	–	–	[117]
Ti	Al6063 TS	He	22	600	1.5	–	–	[118]
Ti	Al₂O₃	N₂	25	450	2.5	2.7	–	[33]
Ti	Mild steel_{(sandblasted)}	N₂	38–44	155–263	2	2	100	[71]
Ti	Mild steel_(polished)	He	38–44	255	1	2	100	[71]
Ti	Iron_(polished)	He	<25	20	2.9	1.35	100	[80]
Ti	Mild steel_(polished)	He	<25	20	2.9	1..35	100	[80]
Ti	SS 304_(polished)	He	<25	20	2.9	1.35	100	[80]
Ti	Martenstitial free _{(sandblasted)}	N₂	44	450	2	2	100	[119]
Ti	Ti	N₂	29	300–800	3; 4	–	–	[119]
Ti	Ti	N₂	16; 22	600	2.4	–	–	[120]
Ti	Ti	He	16	600	1.5	–	–	[120]
Ti	Ti6Al4V	He	5–29	260	1.6	3.8	90	[121]
Zn	Al6061_{(grit blasted)}	He	17; 45	260	2	–	–	[122]
Zn	Zn_(polished)	N₂	5.2–26.4	320	2	2	100	[123]
Zn	Mild steel_{(grit blasted)}	He	5.2–26.4	140	0.5	2	100	[123]
Zn	Mild steel_{(grit blasted)}	N₂	5.2–26.4	165–410	2	2	100	[123]
Al2319	Mild steel_{(sand blasted)}	Air	<63.8	250	2.8	2.7	170	[124]
Ti	Mild steel_{(sand blasted)}	Air	<38.9	250	2.8	2.7	170	[124]
Cu	Mild steel_{(sand blasted)}	Air	<98.5	250	2.8	2.7	170	[124]
Al	Steel_{(33-3300C grit blasted)}	N₂	36	33–500	0.6	–	–	[125]
Zn	Steel_{(33-2450C grit blasted)}	N₂	13	33–500	0.6	–	–	[125]
Sn	Steel_{(33-800C grit blasted)}	N₂	10	33–80	0.6	–	–	[125]
Al	Al	Air	53–75	315	2	2.8	–	[126]
Zn	Al	Air	45–	315	2	2.8	–	[126]
Al	Al	Air	90	290–340	1.5–2	2.8	–	[127]
Al	Bronze	Air	9–40	290–340	1.5–2	2.8	–	[127]
Fe	Al	Air	≤45	480–590	1.5–2	2.8	–	[127]
Fe	Bronze	Air	≤445	480–590	1.5–2	2.8	–	[127]
Cu	Al	Air	≤445	480–590	1.5–2	2.8	–	[127]
Cu	Bronze	Air	≤445	480–590	1.5–2	2.8	–	[127]
Cu	Cu	N₂	10–33	150	1	2.6	–	[128]
Cu	316L SS	N₂	10–33	150	1	2.6	–	[128]
Ni	Cu	N₂	10–33	150	1	2.6	–	[128]
Cu	SS_{(sand blasted)}	N₂	15–37	220	2	2	100	[129]
Ti	SS_(polished)	N₂	37–44	240	2	2	100	[129]
SS 316L	SS 304_{(grit blasted)}	He	16–44	150–300	1.5–3	–	–	[130]
Iron 101	SS 304_{(grit blasted)}	N₂	15–44	200–300	1–3	–	–	[130]
Ti	Mild steel_{(grit blasted)}	air	5–45	250	2.8	2.7	170	[131]
Ti	Mild steel_{(grit blasted)}	N₂	5–45	263	2	2	100	[131]
Ti6Al4V	Mild steel_{(grit blasted)}	Air	5–90	520	2.8	2.7	170	[131]
Al	Mild steel_{(grit blasted)}	Air	5–63	520	2.8	2.7	170	[131]
Al-12Si_{at 1500C}	Al6061 T6_{(grit blasted)}	He	5–65	500	3	–	–	[132]
Al-5Sn	Steel_{(grit blasted)}	He; N₂	20	300	0.7	–	–	[133]
Al-5Sn	Al6061	N₂	20	500	3	–	–	[133]
Al-10Sn	Mild steel_{(grit blasted)}	He; N₂	15	300	0.7	–	–	[133]
Al-10Sn	Cu _(pickled) Al6061(_(pickled)	He; N₂	15.2	300	0.7	–	–	[134]
Al-20Sn	SUS304 _(pickled)	He; N₂	13.8	300	0.7	–	–	[134]
Al-13Co-26Ce	Al_{(grit blasted)}	He	23	200–370	1.7	2	–	[135]
Cu-2Ag-0.5Zr	AlSl 4130_{(grit blasted)}	He	27	500	1.6–2.6	2.7	–	[136]
CuCrAl	GRCop-84	He	10–25	300–500	1.5–2.5	–	–	[137]
Cu-Sn	SS_{(sandblasted)}	He	48	520	2	2	100	[138]
Cu—6Sn	Mild steel	Air	28	500	3	6	170	[139]
Cu-8Sn	Mild steel	Air	17	500	3	6	170	[139]
Diamalloy	Mild steel_(polished)	N₂	<50	800		–	–	[140,141]
T_i2AlC	Al6061	N₂	25–40	500–800	3.8	–	–	[142]
T_i2AlC	Steel_{(grit blasted)}	N₂	25–40	600–800	3.4–3.9	–	–	[142]
Al₂O₃	Al₂O₃	Air	0.5	20	0.4	1 × 1	5	[143]
SiC	Inconel 625_Cleaned	Air	6–33	280	0.6–0.8		–	[41]
WO₃	Si	He	30–50	300	0.7	4 × 6	–	[44]
PPA	HDPE	Air	150–250	20	0.075	5.2	200	[51]
CoNiCrAlY	Al6061_{(grit blasted)}	He	5–37	550	2	2	270	[144]
MCrAiY-Re	Ni_(cleaned)	N₂	10–40	800	4	–	–	[145]
WC-12Co	SS_{(sand blasted)}	N₂	9; 13; 17	750	2.4	2	100	[146]
WC-12Co	WC-12Co	N₂	9; 13; 17	750	2.4	2	100	[146]
WC-12Co	Al7075 T6_(polished)	N₂	10–30	800	3	–	–	[146]
WC-17Co	Al7075 T6_(polished)	N₂	10–30	800	4.4	–	–	[146]
WC-12Co	SS SUS 304_{(grit blasted)}	N₂	15–45	700	3.4	–	–	[147]
WC-17Co	SS SUS 304_{(grit blasted)}	He	15–45	600	1.2–1.5	–	–	[147]
WC-17Co	SS_(cleaned)	He	∼30	600	3–4	–	–	[148]
WC_25Co	Al7075 T6_(polished)	N₂	32	800	3–4	–	–	[149]
WC_25Co	Steel_(polished)	N₂	32	800	3.4	–	–	[149]
WC_CoCr	Al_{(grit blasted)}	He	34 ± 17	550	1.7	–	–	[150]

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