EFFECT OF COLD SPRAYING PARAMETERS ON THE DEPOSITION PERFORMANCE OF ADDITIVELY MANUFACTURED Ti6Al4V ALLOY

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Cold Spray (CS) is a solid-state coating technology where metal powders are propelled at supersonic velocities to form dense coatings via severe plastic deformation upon impact, without melting. This mechanism preserves the feedstock material's integrity by minimizing thermal degradation, such as oxidation and residual stresses, making it ideal for surface refurbishment and restoration in thermally sensitive applications. In this study, CS deposition was sprayed onto a Ti6Al4V substrate (60x60x4 mm³) fabricated via Selective Laser Melting (SLM), using spherical Ti6Al4V powders with a particle size distribution of 0–20 µm. The primary objective was to optimize CS process parameters to observe coating integrity and interfacial adhesion. Considering the limitations of low-pressure spraying, temperature, nozzle-distance, and advancement speed were fixed at constant values, while gas pressure and powder feed rate were systematically varied. Coating characteristics, including thickness, homogeneity, surface morphology, and adhesion—were evaluated through scanning electron microscopy (SEM). Subsequently, under the previously optimized selected parameter set, the effect of different advancement speeds (10, 20, 30, and 40 mm/s) on the accumulation behavior was analyzed.