Impact behaviour of lightweight metal component repair using aluminium particles with high pressure cold spray process and low-pressure cold spray process

This study focuses on impact behaviour of lightweight metal repair using aluminium powder by high pressure cold spray process (HPCS) and low-pressure cold spray process (LPCS). The aluminium particles impacting on aluminium substrates using LPCS process deformed slightly with the smallest flattening ratio that leads to less pore formation between the particles and resulted in good coating quality. Moreover, LPCS deposition experiences compressive stress that ensures longer component lifetime due to its positive effect on the fatigue life and wear resistance application. The overall results denote that LPCS process is better for repairing lightweight metal component than HPCS process.