The Cold Spray process basically uses the energy stored in high pressure compressed gas to propel fine powder particles at very high velocities (500 - 1500 m/s). Compressed gas is fed via a heating unit to the gun where the gas exits through a specially designed nozzle (level type convergent-divergent nozzle mostly) at very high velocity. Compressed gas is also fed via a high pressure powder feeder to introduce powder material into the high velocity gas jet. The powder particles are accelerated and moderately heated to a certain velocity and temperature where on impact with a substrate they deform and bond to form a coating. As with the other processes a fine balance between particle size, density, temperature and velocity are important criteria to achieve the desired coating.

• Recovery of the shape and size of parts;
• Creating electrical contact pads;
• Elimination of moulding and mechanical defects;
• The elimination of leaks of liquids and gases (sealing);
• Corrosion protection;
• Protection "setting" (EP coating);
• Prevent sparking;
• Recovery anti-friction coating of plain bearings;
• Decoration.

The main properties of the coatings

• High adhesion (30-80 MPa);
• High cohesion (30-80 MPa);
• Homogeneity of the surface;
• Low porosity (1-3%);
• High electrical conductivity between the coating and the substrate;
• Any coating thickness (20 microns to 10 cm);
• Roughness of the surface coating is Rz = 20-40;
• Processing coatings produced by conventional machining methods;
• Coating may be applied to any metal, glass and ceramics.