Thick metal/diamond composite coatings on Al substrate weredeposited by cold spray process with in-situ powder preheating.Microstructural characterization of the as-sprayed coatings withdifferent diamond size, strength and with/without Ti cladcoating was carried out by OM and SEM. Assessment of basicproperties such as tensile bond strength, porosity, and hardnessof the coatings and the deposition efficiency was also carriedout. Particular attention on the coatings was on the diamondfracture phenomenon during the cold spray deposition and theinterface bonding between diamond and metal matrix. Thepotentials and the problems of metal/diamond compositecoatings by cold spray are discussed.
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