In the world of surface engineering, cold spray technology has long been a go-to method for creating dense, high-adhesion coatings. However, its efficiency has often been hampered by thermal and kinetic limitations. Enter Oleksandr Shorinov, a researcher from the National Aerospace University “Kharkiv Aviation Institute” in Ukraine, who has developed an innovative strategy to enhance the deposition efficiency of cold spray coatings. His work, published in the journal “Materials Research Express” (which translates to “Expressions of Material Research”), could have significant implications for industries like aerospace and energy.
Shorinov’s study focuses on redesigning the gas heating system of a low-pressure cold spray (LPCS) machine. The crux of his innovation lies in a novel heater with increased power. “We developed a heater with 5.3 kW of power, compared to the standard 3.3 kW,” Shorinov explains. This might seem like a modest upgrade, but it’s a game-changer. The new heater compensates for the temperature drop associated with higher gas stagnation pressures, enabling stable gas heating to 605 °C at an inlet pressure of 1.0 MPa. In contrast, the standard configuration could only achieve 373 °C under the same conditions.
The impact of this improvement is substantial. The increased gas temperature boosts the velocity and temperature of powder particles in the nozzle flow, leading to enhanced particle deformation and adhesion upon impact. “This significantly increased the thickness of aluminum coatings deposited on titanium substrates,” Shorinov notes. In fact, under identical spraying conditions, the coating thickness increased more than fivefold. Deposition efficiency saw a dramatic rise from 13.4% with the standard heater to 60.6% with the developed heater.
The practical implications of this research are vast. In industries like aerospace and energy, where high-quality, defect-free coatings are crucial, this innovation could lead to more efficient and reliable coating processes. “This approach offers a practical pathway for optimizing cold spray technology,” Shorinov states. By simply modifying the heating system, industries could see significant improvements in both the effectiveness and reliability of their coating processes.
The study also confirmed the formation of dense, homogeneous coatings with strong interfacial bonding and reduced porosity. This is a critical factor in ensuring the longevity and performance of coated components, particularly in harsh environments.
As we look to the future, Shorinov’s research opens up new possibilities for advancements in cold spray technology. It underscores the importance of optimizing thermal and kinetic parameters to achieve superior coating qualities. For professionals in the energy sector and beyond, this study serves as a reminder that sometimes, the most significant improvements come from relatively simple yet innovative modifications. As the energy sector continues to evolve, such advancements will be crucial in meeting the demands for high-performance, durable materials.