Surface Engineering

ISSN: 0267-0844 (Print) 1743-2944 (Online) Journal homepage: http://www.tandfonline.com/loi/ysue20

Mainstreaming cold spray push for applications

V. K. Champagne & D. J. Helfritch
To cite this article: V. K. Champagne & D. J. Helfritch (2014) Mainstreaming cold spray push
for applications, Surface Engineering, 30:6, 396-403, DOI: 10.1179/1743294414Y.0000000277
To link to this article: http://dx.doi.org/10.1179/1743294414Y.0000000277

Published online: 07 May 2014.

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Date: 13 October 2016, At: 08:35

REVIEW

Mainstreaming cold spray push for

applications
V. K. Champagne and D. J. Helfritch*
Modern cold spray, first implemented 30 years ago, has since expanded rapidly in system
designs and applications. While initially considered to be a method to deposit a ductile metal
coating onto another metal, subsequent innovations in design and use have allowed new
applications to areas as diverse as medical and electronics. This paper describes some new
methods and applications that are currently being developed. Twenty-four new applications are
presented, chosen to represent the diversity of actual and potential uses of cold spray
technology.
Keywords: Cold spray, Applications, Corrosion, Electronics, Plastics, Medical

This paper is part of a special issue on cold spray technology

Introduction
Cold spray was initially developed in the mid-1980s at
the Institute for Theoretical and Applied Mechanics of
the Siberian Division of the Russian Academy of Science
in Novosibirsk.1,2 The Russian scientists demonstrated
that very high coating deposition rates are attainable.
These early efforts are being expanded upon at
institutions in dozens of locations world-wide. Unlike
most thermal spray processes, cold spray is based upon
high velocity, solid state, particle impact, rather than
high temperature, melted particle, impact.
Since its initial development, cold spray has been in
competition with other, well established, thermal spray
systems. In order to identify applications most suitable to
cold spray, a potential application should require the
attributes of cold spray low temperatures, dense packings,
and compressive stress. Accordingly, cold spray methods
are being developed for many new coating applications with
such requirements. These applications range from environmentally driven substitutions to biomedical implants.
The requirements of these new applications range from
corrosion protection to radiation blocking.
The work described in this paper describes efforts toward
the development of new applications. Some efforts are
relatively preliminary while others are being commercially
implemented; however, all efforts described are directed
toward a new application or an improvement to an existing
application.

Medical devices
Bone implants
The bioceramic Hydroxyapatite, Ca10(PO4)6(OH)2, also
known as HAP has been widely used in dental and
orthopedic implants, due to its chemical and crystallographic
US Army Research Laboratory and Dynamic Science, Inc., MD, USA
*Corresponding author, email dennis.j.helfritch.ctr@mail.mil

396

2014 Institute of Materials, Minerals and Mining

Published by Maney on behalf of the Institute
Received 15 January 2014; accepted 19 March 2014
DOI 10.1179/1743294414Y.0000000277

similarity with bone minerals. HAP has been conventionally

deposited by plasma spray technique; however, due to the
high temperature of the plasma spray, deleterious effects such
as evaporation, phase alteration, residual stress, debonding,
and gas release commonly occur in these coatings.
Researchers at the University of Michigan have
developed a method to deposit bioceramic coatings at
temperatures well below their melting point by cold
spray, using composite powders of titanium and HAP.3
Although the cold sprayed surface is not pure HAP, the
implant need not be completely covered by HAP for biointegration with surrounding tissue, and in fact implant
surfaces consisting of a fraction of area covered by HAP
can effectively integrate to the bone.
The influence of the process parameters, powder type
as well as HAP to titanium ratio were investigated, and
it was observed that dense composite coatings, containing up to 30% HAP can be deposited by this technique.
Figure 1 is a micrograph of the deposit. X-ray diffraction analysis indicated that the phase composition of the
HAP in the deposit was identical to that of the powder.
It was demonstrated that HAP powders can be cold
sprayed simultaneously with titanium to form thick
biocompatible composite coatings, without compromising the phase constituents of HAP. Despite its ideal
bioactive properties, poor mechanical strength hinders
the use of pure HAP as a load bearing implant. As a
result, the combination of bioactive HAP coating and
mechanically strong metals has become a promising
approach to fabricate surgical implants for load-bearing
applications. Coatings deposited using this process hold
potential for improving bone integration of a wide range
of dental and orthopaedic implants.

Antimicrobial
Bacterial contamination on touch surfaces results in
increased risk of infection. In the last few decades, work
has been done on the antimicrobial properties of copper
and its alloys against a range of micro-organisms
threatening public health in food processing, healthcare

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Mainstreaming cold spray

3 Corrosion on H-53 tail gearbox housing5

Protection from corrosion

1 Magnied cross-section of Sponge-Tiz20% HAP coating3

and air conditioning applications; however, an optimum

method of copper surface deposition and the resulting
mass structure has not been identified.
In order to identify ideal deposition methods and
deposit characteristics the US Army Laboratory conducted a study of the disinfection effectiveness of three
copper surfaces.4 The surfaces were produced by the
deposition of copper using three methods of thermal
spray, namely, plasma spray, wire arc spray and cold
spray. The surfaces were subsequently inoculated with
meticillin-resistant Staphylococcus aureus. After a two
hour exposure to the surfaces, the surviving S. aureus
were assayed and the results compared.
The cold spray deposition method was significantly
more effective than the other methods. It was determined that work hardening caused by the high velocity
particle impacts created by the cold spray technique
results in a copper microstructure that enhances ionic
diffusion, which subsequently improves antimicrobial
activity. As an example of how these results can be
implemented, Fig. 2 shows a hospital table, coated with
cold sprayed copper.

2 Hospital table coated with cold sprayed copper4

Cold sprayed coatings are unique within thermal spray

coatings for extremely dense and impervious characteristics. Accordingly, much effort has been devoted to
developing cold spray coatings for the protection of
corrosion susceptible materials. Perhaps the most
investigated corrosion protection application is the use
of cold sprayed aluminium for the protection of
magnesium. This application will be examined, followed
by a summary of related applications.
Magnesium is approximately 35% lighter than aluminium and has exceptional stiffness and damping
capacity. Accordingly, Mg alloys, because of their high
strength-to-weight characteristic, are used for the
fabrication of many components on military aircraft,
especially for complex components such as transmission
and gearbox housings on helicopters and fixed-wing
aircrafts.
Magnesium is a very active metal electrochemically
and is anodic to all other structural metals. Therefore, it
must be protected against galvanic corrosion in mixedmetal systems because it will corrode preferentially when
coupled with virtually any other metal in the presence of
an electrolyte or corrosive medium. Many of the
corrosion problems associated with Mg helicopter
components occur at the contact points between ferrous
metal inserts or mating parts, creating galvanic couples.
Much of the corrosion occurs at attachment points
where a dissimilar metal is in contact with the Mg
component. These include flanges, mounting pads, tie
rods, lugs, and mounting bolts. Figure 3 shows the
extent of localised corrosion damage on one of the
mounting pads of an H-53 tail gearbox after one
overhaul cycle.
The military and the aerospace industry have
expended much effort over the last two decades to
develop specific surface treatments to prevent corrosion,
to increase surface hardness, and to combat impact
damage for Mg alloys in order to prolong equipment
service life. However, the means to provide dimensional
restoration to large areas on components where deep
corrosion has occurred remains a challenge. The use of
the cold spray process to deposit commercially pure
aluminium for providing dimensional restoration and
protection to magnesium has been developed by the US
Army Research Laboratory Center for Cold Spray
Technology.5 The cold spray process was viewed as the
best possible method for depositing aluminium coatings
onto Mg and is viewed as part of an overall strategy
of replacement of the environmentally unacceptable

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Mainstreaming cold spray

4 Salt spray testing of bare and cold sprayed magnesium panels. Before exposure shown on left, after exposure on
right5

chromate processes currently in use today, eliminating

environmental and worker safety issues, while significantly improving performance and reducing lifecycle
costs.
The evaluation program for magnesium protection by
cold sprayed aluminium included tests for corrosion
resistance, bond strength, hardness and microstructure.
Corrosion test panels were prepared using a nitrogen
carrier gas. The edges of the panels were sealed with
epoxy so only the front and back surfaces were exposed
to the salt spray. The panels were exposed to salt spray
according to the requirements of ASTM B117. The
results are shown in Fig. 4, where, except for some
discoloration of the aluminium, no corrosion is evident
on the panel that was cold sprayed with aluminium.
Related studies of cold sprayed coatings for corrosion
protection are listed in Table 1. This table gives the cold
sprayed coating material and the substrate to be

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protected. In all cases, the processes resulted in good

protection when properly carried out.
The cold spray method for repairing and protecting
magnesium aircraft surfaces is currently being commercialised by a major US helicopter manufacturer.

Electronics
Solder surfaces
The superior electrical and thermal conductivities of
cold sprayed copper and copper alloy deposits make
cold spray well suited for electronics manufacture. In
addition, cold spray allows the placement of lead-free
connectors. Cold spray application to power electronics
is of particular interest, since ceramics are often used as
insulating substrates. Rastjagaev et al.13 seek to replace
a sandwich of copper-alumina-copper, normally utilising direct copper bonding, with cold sprayed copper on

Champagne and Helfritch

Mainstreaming cold spray

6 Soldered power transistor on aluminium heat sink with

cold sprayed copper layer14

5 Cold sprayed
strate13

Al/Cu

metallisation

on

alumina

sub-

alumina (see Fig. 5). They found that cold sprayed

copper, preceded by a cold sprayed aluminium base on
the alumina ceramic, closely matched the characteristics
of direct copper bonding.
Cold sprayed copper can provide a solderable surface
onto substrates that do not accept wetting by solders.
Aluminium with oxides present is such a substrate. Marx
et al.14 show that copper can be cold sprayed onto an
aluminium heat sink, allowing a power transistor to be
soldered to the copper layer (see Fig. 6). The cold
sprayed copper layer removes the natural oxide film and
provides a solderable surface for the tin- or copperplated area of electronic parts. In addition, the copper
layer conducts the heat very rapidly from the electronic
part to the heat sink.

Micro circuitry
The application of fine line micro-circuitry onto ceramic
substrates currently requires a multi-step process including printing, baking and sintering. A new one-step
process, utilising particle acceleration by means of flow
through a capillary, directs a high velocity stream of
copper particles within a helium carrier onto a ceramic
substrate.15 Upon impact the particles deform and
adhere to the substrate and to previously deposited
particles, as for conventional cold spray. The use of a
capillary tube as the flow nozzle restricts the jet and the
resulting deposited copper to micron scale dimensions.
The deposited copper is dense, with near zero porosity.
Robot control of the jet position can yield precise
conduction lines and component connections.
Particles, accelerated by high-pressure helium through
a 125 mm ID capillary, produced the copper line shown
in Fig. 7. The dense, non-porous nature of the deposit is
consistent with that for conventionally cold sprayed

copper and indicates good tensile strength and electrical

conductivity, which are typically 300 MPa and
80%IACS, respectively.
Akhatov et al.16 demonstrated similar fine line
writing, using a silver ink aerosol, helium gas, and a
capillary converging from 800 to 100 mm at the exit.
A two orders of magnitude reduction of line width
from conventional cold spray to capillary cold spray has
been achieved. Capillary cold spray can produce copper
conducting lines usable in MEMs circuits without the
need for post-deposition heat treatments. Robotically
controlled line writing is accurate and rapid. In addition,
capillary deposition of copper and silver can be
applied as a solderless connector for board mounted
components.

Structures
Although generally used for coatings, there is no
theoretical limit to the thickness that a cold sprayed
deposit can achieve. Thick (tens of centimetres) deposits
are frequently cold sprayed from many feedstock
powders. Accordingly, the cold spray process is capable
of creating 3D shapes of various geometries. Several
shapes have been created by cold spray at the US Army
Research Laboratory.17 One such example is shown in
Fig. 8 for a NiAl powder.
Cold spray generated finned heat exchangers have
been produced by Canadian researchers.18 These structures were created using masks of wire screen mesh. The
motivation for these heat exchangers is heat recovery in
micro-turbines. By spraying over the mesh, pyramidal
structures were formed on the substrate below. These
structures serve as fins in conventional heat transfer. The
pyramids produced were typically 2 mm in height.
Convective heat transfer by the cold spray deposited
pyramidal fins was found to be superior to that of
conventional square cut fins, especially at higher
Reynolds numbers (gas velocities).

Table 1 Efforts in protective cold sprayed surfaces

Reference

Coating

Substrate

DeForce et al.6
Chavan et al.7
Koivuluoto et al.8
Koivuluoto et al.9
Ma et al.10
Marrocco et al.11
Wang et al.12

Al5%Mg, CPAl, HPAl, AA5356, AA4047

Zinc
Tantalum
Ni, NiCu
Aluminium
Titanium
Titanium

ZE41AT5 Mg
Steel
Steel
Steel
NdFeB
Steel
Steel

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Mainstreaming cold spray

7 Capillary deposited copper line on aluminium15

9 Cold spray deposit of TiO2 on steel substrate19

Catalyst deposition

of oxidised nitric oxide following contact with the UV

irradiated TiO2. In most cases, the deposited material had
more activity than that of the feedstock material. This was
explained as surface area being exposed through impact
fissures.
Yang et al.21 compared cold sprayed TiO2 with that of
HVOF sprayed material and showed much greater
photodegradation effectiveness of acetaldehyde for the
cold sprayed material (see Fig. 11). X-ray diffraction
analysis indicated that the cold sprayed TiO2 film is in
pure anatase phase, while HVOF sprayed TiO2 coating
is composed of both anatase phase and rutile phase.

The ability of cold spray to maintain powder particles at

low temperatures prevents many crystalline transformations that would occur for higher temperature thermal
spray processes. For example, titanium dioxide (TiO2) is
a promising material for photocatalyst coatings; however, it is difficult to fabricate a TiO2 coating with a
photo catalytically active anatase phase by conventional
thermal spray processes due to a high temperature
thermal transformation to rutile phase. Low temperature cold spray deposition allows initially anatase
powder to remain in that phase after deposition.
As a ceramic, TiO2 is difficult to deposit. Researchers
at Toyohashi University of Technology19,20 have developed a process to cold spray ceramic TiO2 onto
appropriate surfaces using helium as the accelerating
gas. A cross-section of the TiO2 deposit on steel is shown
for inlet gas temperature of 400uC is shown in Fig. 9.
TiO2 particles deposit upon previously deposited particles, showing that depositions thicker than one layer of
particles is possible. This was also possible when using
nitrogen as the accelerating gas. X-ray diffraction
spectra showed that the deposited material maintained
the anatase crystal phase.
The catalytic activity of the deposited coatings was
compared with that of unsprayed feedstock powder in
Fig. 10. Catalytic activity was measured as the percentage

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Plastic powders
The use of cold spray to deposit polymers, or to deposit
onto polymers is very difficult, since polymers are quite
different than the ductile metals usually associated with
cold spray deposition. Several researchers have successfully done this, but at significantly different operating
conditions than normally used in cold spray.
After many trials, researchers at the South Dakota
School of Mines were able to define a cold spray nozzle
and operating conditions that allow the deposition of
polyethylene powder onto aluminium.22 Computational
Fluid Dynamics (CFD). analysis was used to design an
appropriate nozzle and experiments revealed an optimum inlet gas pressure. It was found that, under specific
conditions, a uniform deposit of polyethylene could be
produced.

10 NO elimination upon contact with UV irradiated TiO2,

for pure powder, nitrogen sprayed powder and helium
sprayed powder20

8 3D shape produced by cold spray17

400

Plastics

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11 Change of relative concentration of acetaldehyde with

degradation time21

Researchers at Cambridge University developed

methods to deposit polyolefin powder.23 They found
that the powder would deposit and consolidate readily
on polyethylene substrates but that aluminium substrates needed to be heated before deposition occurred.
Both groups of researchers did not allow polymer
melting and found that low impact velocities
(y100 m s1) were necessary to avoid erosion of the
deposit. Figure 12 shows a cross-section of cold spray
deposited polymer.

Plastic substrates
Researchers at the Toyohashi University of Technology
deposited copper onto two, dissimilar, polymer substrates, PVC and epoxy.24 They found that the impact of
copper particles have significantly different results on
the two substrates. PVC tends to envelope particles,
while shattered craters form on epoxy. In both cases,
however, successful copper deposits could be produced
when a preceding layer of tin is applied by cold spray
(see Fig. l3).
Lupoi and ONeill at Cambridge University cold
sprayed several powders onto several polymer substrates.25 The substrates were untreated commercial
polycarbonate, ABS blend (PC/ABS), polystyrene,

12 Cold spray deposited polymer23

Mainstreaming cold spray

13 Deposition of copper layer over epoxy, with tin interlayer24

polyamide-6, polypropylene and a glassfibre composite

material. Failing to deposit copper or aluminium, they
found that an ideal material to obtain metal deposition
on plastic or composite substrates is tin, characterised by
both low density and critical speed, in order to avoid
erosion of the substrate. This result is similar to that
found at the Toyohashi University of Technology,
above. Lupoi and ONeill did not attempt to apply a
secondary coating over the tin, but it is assumed that it
would be possible.

Electromagnet transmission
Deposition of antennas
Large antenna arrays mounted directly on the surface of
load bearing aircraft wings and structures permit
implementation of future communications systems without the aerodynamic drag of protruding antenna.
Current techniques for fabricating conformal antennas
are difficult to apply to the shapes of high performance
aircraft. Large, irregular, and doubly curved surfaces
such as those found on the wings and tail of an aircraft
are more difficult to populate with antenna substrates
and radiating elements.
The Inovati Corporation has been developing a direct
write method of fabricating metallic antenna structures
onto doubly curved dielectric surfaces using the low
temperature kinetic metallisation (KM) process.26 The
KM process is similar to cold spray in that it deposits
high velocity particles, which have been accelerated in a
nozzle. The technology can enable fabrication of low
profile RF systems on current and planned airborne
platforms. The wireless military and commercial communication industry are interested in the manufacture of
large-scale antenna systems.
In order to demonstrate the main innovation of
applying high quality RF conductor patterns in complex
net shape geometries via KM, a doubly curved fourelement antenna array was fabricated with KM deposition of copper onto RO3003 dielectric (Teflon with fused
silica composites). Figure 14 shows the completed
antenna. RF testing performed with the KM copper
coatings showed that the electrical characteristics of the
conductor deposited using the KM process is similar to

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Mainstreaming cold spray

14 Copper deposition onto curved dielectric surface26

that made using conventional etched copper foil

techniques on identical RO3003 dielectric materials.

Electromagnetic shielding
Electromagnetic shielding prevents radiated electrical
signals from reaching destinations where their presence
is undesirable. There are two purposes for the shielding
of electronics enclosures. The first is to prevent external
electromagnetic sources from penetrating a sensitive
environment containing electronic equipment, which is
susceptible to interference from the unwanted signals.
The second purpose for shielding is to prevent electromagnetic signals generated by equipment within the
facility from being transmitted or conducted in sufficient
magnitude to be received by external receiving and
signal recovery systems.
The S-778, lightweight multipurpose shelter (LMS) is
a transportable, rigid wall, tactical shelter, mounted on a

high-mobility multipurpose wheeled vehicle. The LMS

provides a lightweight shelter for a broad range of
battlefield electronic systems. The LMS is constructed
from 3 cm thick panels consisting of aluminium skins
that encase a fibrous honeycomb inner core. The bonded
panels contain many aluminium to aluminium seam
joints. Panels that have been bonded with adhesives
present shielding problems, because electrical contact
across the seam is lost due to the dielectric nature
of organic adhesives. Conductively sealing the seams
by means of flowing metal, such as brazing, cannot
be done, because of the temperature limitations of
adhesives.
Engineers at the US Army Research Laboratory have
demonstrated that the cold spray technique for metal
particle deposition has been shown to yield dense,
conductive coatings on aluminium surfaces.27 Since
application temperatures are relatively low (,100uC),
nearby adhesives are not damaged. While cold spray is
often carried out with a stationary robot controlled
system, the large panel size (363 m) and field application favoured the use of a hand-held portable system.
This portable unit used shop supplied compressed air as
opposed to the significantly higher pressures used by
stationary units. The coatings produced by cold spray
exhibited good bond strength to aluminium, and their
density provided high resilience to vibrations. Figure 15
shows how a seam is filled with aluminium deposit by
cold spray.

Concluding remarks
The cold spray applications described here represent a
small percentage of the new application efforts currently

15 Sealing seams of electronics enclosure with cold sprayed aluminium27

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being carried out worldwide. Much new work is

proprietary in nature, and is not public. Research level
work was presented, as well as applications that are near
commercial use. Twenty-four individual projects were
described, and the wide range of applications possible
with cold spray technologies is evident from medical
implants to radiation shielding. The scope of these
efforts is indicative of the confidence of the cold spray
community of a promising future.

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