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Coatings
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Cold Spray for Additive Manufacturing and Remanufacturing Applications
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Cold Spray for Additive Manufacturing and Remanufacturing Applications

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Functional Polymer Coatings and Films".

Deadline for manuscript submissions: 25 January 2026 | Viewed by 1489

Special Issue Editors

Dr. Wen Sun

E-Mail Website
Guest Editor
National Engineering Laboratory of Modern Materials Surface Engineering Technology, Guangdong Provincial Key Laboratory of Modern Surface Engineering Technology, Institute of New Materials, Guangdong Academy of Sciences, Guangzhou 510650, China
Interests: coatings; cold spray; additive manufacturing; tribological properties
Special Issues, Collections and Topics in MDPI journals
Dr. Ruitao Li

E-Mail Website
Guest Editor
School of Mechanical Engineering, Jiangsu University, Zhenjiang 212013, China
Interests: interface control and strengthening mechanisms of metal matrix composites; preparation and characterization of thermal spray coatings; development of advanced biomaterials and energy materials

Special Issue Information

Dear Colleagues,

Cold Spray technology, a solid-state deposition process where particles are accelerated to supersonic velocities and bonded upon impact with a substrate, has gained significant traction in recent years. Originally developed for corrosion and wear-resistant coatings, Cold Spray has now emerged as a critical technique in the fields of additive manufacturing (AM) and remanufacturing. Unlike traditional thermal spray methods, Cold Spray operates at lower temperatures, preserving the inherent properties of feedstock materials and reducing thermal stresses. This unique characteristic makes it an ideal candidate for fabricating near-net-shape components and repairing high-value parts in industries ranging from aerospace to biomedicine.

The aim of this Special Issue is to compile cutting-edge research and advancements in the application of Cold Spray technology for additive manufacturing and remanufacturing. This compilation will provide a comprehensive overview of the current state of the art, highlight innovative approaches, and identify future directions for research and industrial applications. This Special Issue will serve as a valuable resource for researchers, engineers, and practitioners in the field, facilitating knowledge exchange and fostering collaboration. We are pleased to invite you to submit contributions from academia and industry, and researchers are encouraged to submit original research articles, review papers, and case studies that provide valuable insights into and advancements in the field of Cold Spray technology for additive manufacturing and remanufacturing applications.

The scope of this Special Issue cover, but is not limited to, the following topics:

  • Novel Cold Spray materials and techniques for additive manufacturing;
  • Cold Spray technology’s applications in surface repair, surface enhancement, functional coatings, and additive manufacturing in many fields, including the aerospace, armament, energy and power, electronic power, and medical equipment industries;
  • Unique attributes of Cold Spray, such as a high deposition rate, high adhesion strength, solid-state bonding at low temperatures, etc.;
  • The integration of artificial intelligence (AI) technology with Cold Spray helps to better realize toolpath and process optimization, as well as process control for industrial production campaigns;
  • Cold Spray repair and remanufacturing of worn or damaged components;
  • Characterization and testing of Cold-Sprayed components for additive manufacturing and remanufacturing applications;
  • Challenges and opportunities related to implementing Cold Spray technology for additive manufacturing and remanufacturing.

We look forward to receiving your contributions.

Dr. Wen Sun
Dr. Ruitao Li
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • cold spray additive manufacturing
  • cold spray remanufacturing
  • cold spray repair and restoration
  • cold spray fundamentals
  • cold spray of novel and functional materials
  • artificial intelligence in cold spray

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (2 papers)

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Research

15 pages, 12810 KiB  
Article
Cold Spray Preparation of High-Performance Anti-Cavitation Copper Coatings on Steel Substrates
by Yunzhen Pei, Zhongwu Sun, Weijie Liu, Chunming Deng, Jiayan Ma, Haiming Lan, Xin Chu and Yingchun Xie
Coatings 2025, 15(4), 381; https://doi.org/10.3390/coatings15040381 - 25 Mar 2025
Viewed by 345
Abstract
Copper and its alloys are widely used in marine environments due to their excellent corrosion resistance and thermal conductivity. Cold spray technology can avoid the thermal damage to the underlying material and is suitable for the manufacturing and repair of parts. In this [...] Read more.
Copper and its alloys are widely used in marine environments due to their excellent corrosion resistance and thermal conductivity. Cold spray technology can avoid the thermal damage to the underlying material and is suitable for the manufacturing and repair of parts. In this study, Cu coatings were prepared on 304 stainless steel substrates by high-pressure cold spray technology, and the effects of cold spray parameters on the microstructure, mechanical properties, and cavitation resistance were investigated. The coatings (Cu-N21, Cu-N22, and Cu-He) were prepared using distinct cold spray parameters: Cu-N21 and Cu-N22 employed nitrogen gas at 5 MPa/800 °C with different nozzle geometries, while Cu-He utilized helium gas at 3 MPa/600 °C. The results show that the porosity of the Cu coating prepared by cold spray technology is less than 0.1%. The coating treated with helium gas exhibits a higher bonding strength (81.3 MPa), whereas the coating treated with nitrogen demonstrates greater strain hardening (130–136 HV0.1). XRD results show that no phase change or oxidation occurred for coatings under all cold spraying conditions. After the cavitation test, the mass loss of the Cu coating is significantly less than that of the as-cast copper. The Cu coating surface first develops holes, and with the increase in cavitation time, the hole area begins to increase. However, with prolonged cavitation exposure, the surface of as-cast copper has a large area of holes, and with the increase in cavitation time, the hole growth rate is faster. These observations indicate the cavitation resistance of the Cu coating prepared by cold spray is more than 10 times higher than that of the as-cast copper. This study highlights the potential application of cold spray technology in the preparation of high-performance anti-cavitation copper coatings. Full article
(This article belongs to the Special Issue Cold Spray for Additive Manufacturing and Remanufacturing Applications)
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18 pages, 18527 KiB  
Article
Microstructure and High-Temperature Oxidation Behavior of Cold-Sprayed CoNiCrAlY Coatings Deposited by Different Propellent Gases
by Xundong Sun, Haitao Yun, Wen Sun, Yingchun Xie, Jibo Huang and Zhigang Zheng
Coatings 2025, 15(2), 123; https://doi.org/10.3390/coatings15020123 - 21 Jan 2025
Viewed by 782
Abstract
CoNiCrAlY coatings are widely used as typical high-temperature materials to enhance the surface performances of nickel-based superalloy materials, which can be used as bond coats in thermal barrier coatings and abradable seal coatings. In this study, high-pressure cold spray technology was used to [...] Read more.
CoNiCrAlY coatings are widely used as typical high-temperature materials to enhance the surface performances of nickel-based superalloy materials, which can be used as bond coats in thermal barrier coatings and abradable seal coatings. In this study, high-pressure cold spray technology was used to deposit CoNiCrAlY coatings on nickel-based superalloy substrates. The microstructure characteristics and oxidation behaviors of CoNiCrAlY coatings prepared by different gas types and cold spray parameters were systematically investigated. EBSD analysis showed that the deformation of the helium coating was more distinct, and the grain size of the coating fabricated by helium was smaller than that by nitrogen as seen from the grain morphology. The high-temperature oxidation results showed that the coating oxide film thickness varied parabolically with time for both coatings after 500 h isothermal oxidation at 800 °C, 900 °C, and 1000 °C, and the oxidation rate of the coating after heat treatment was lower than that of the as-sprayed coating. In addition, the shrinkage of the aluminum reservoir inside the coating, the element diffusion rate, and the amount and type of oxide generation on the surface all affected the oxidation process. Additionally, the helium coating had a lower oxidation growth rate and better oxidation resistance. Therefore, cold spray can be an alternative way to fabricate high-quality CoNiCrAlY coatings. Full article
(This article belongs to the Special Issue Cold Spray for Additive Manufacturing and Remanufacturing Applications)
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