What Is High-Pressure Cold Spray?
Cold Spray is a newer advancement in spray processing based on a supersonic gas jet that accelerates the coating powder particles to Mach 2-3 (600-900 m/s). It reflects a trend toward higher particle velocity and lower heat input that began with experiences in the field of High Velocity Oxy-Fuel (HVOF). With Cold Spray, however, the coating materials aren’t melted by a thermal energy source. Rather, the kinetic energy of the coating material is converted to heat by the high velocity of the particles impacting the surface to be coated. As a result, a strong bond is formed with the substrate, similar to explosion welding.

How Does Cold Spray Compare to Other
Thermal Spray Processes?
With Cold Spray, different spray materials can be deposited without subjecting them or the substrate to high thermal loads. Compared to other thermal spray processes, such as Plasma Spraying or Combustion Processes, Cold Spray allows coatings with extremely low porosity and an extremely low oxygen content to be produced (formed).

What Are the Advantages of Cold Spraying?
The wide array of coatings that can be produced by this newer spray technology demonstrate its significant impact. While a variety of spray materials – ranging from relatively low-melting aluminum alloys to temperature sensitive tantalum and niobium – can be applied to a wide variety of substrates, the properties of the deposited layer are nearly impossible to distinguished from the base material.

• No or almost zero oxidation
• +99% dense coating structure if required
• Exceptionally high deposit efficiency

What Industries Benefit from Cold Spray?
Cold Spray is helping to advance a variety of industries, including aerospace, electronics and medical. These sectors place high demands on the mechanical, physical and chemical properties of materials. Since corrosion and material fatigue constitute a high risk potential, Cold Spray has been used to coat aluminum components that are subjected to dynamically high stresses. This enhancement makes high-performance functional surfaces and commercially viable repair methods more accessible than ever.

What Are Recent Developments of Cold Spray?
Cold Spray activities began as early as 2000 between Linde Group, ASB Industries Inc., CRP Automationstechnik AG and Germany’s University of the Federal Armed Forces. In a relatively short time, the newly founded company CGT Cold Gas Technology GmbH developed and launched proven production systems for Cold Spray. At the end of 2002, the first industrial user produced automotive components allowing benefits of this promising process by applying pure copper coatings to aluminum heat sinks.

What Are the Latest Developments in Cold Spray?
The latest developments in Cold Spray have led to process optimization using standard powders and high deposition efficiency. With KINETIKS 4000, the Cold Spray process can compete commercially with any other coating technology on the market. Using cost-effective nitrogen as the process gas, mechanical coating properties – which compare to those of solid materials – can be achieved.

What Is the Future of Cold Spray?
Cold Spray will reveal new coating possibilities, including metallic materials and metal, ceramics or plastic composites. Twenty new applications – which were never before considered within the context of thermal spraying – have already been implemented.

• CGT 4000 AND CGT 3000 EQUIPMENT
• High-Pressure Nitrogen and Helium Infrastructure, Including Nitrogen DESY System New to North America
• Member of the Linde Competency Group, Including All Facets R&D, Equipment, Gas and Material Supply Chain
• Large-Production Spray Capabilities, Including Six Axis Robotic Capabilities – Multiple Work Cells
• Powder Mixing and Drying Facility
• ASB In-House Metallurgical Lab

How Do I Select the Right Cold Spray Material?
Achieving a high-performance surface requires the selection of the correct material. ASB Industries works with the well-known powder manufacturers to optimize powder properties and extend the range of spray materials. While a large spectrum of powders is available upon request, common powders include:

• Copper
• Nickel
• Metal Matrix Composites
• Tantalum
• Niobium
• Aluminum
• Titanium

For research and development studies, production and turnkey equipment, and other technical support, contact the experts at ASB Industries now. Cold Spray – the process that is revolutionizing the thermal spray industry.