The deposition and consolidation of metal powders by means of cold spray is a method where powder particles are accelerated to high velocity through entrainment in a gas undergoing expansion in a de Laval nozzle and are subsequently impacted upon a surface. The impacted powder particles form a consolidated structure which can be several centimeters thick. The characteristics of this structure depend on the initial characteristics of the metal powder and upon impact velocity. Initially soft particles are strain hardened during impact, resulting in a structure that can have a hardness value greater than that which can be achieved by conventional cold working. A materials model is proposed for these phenomena, and model calculation is compared with experimental data from cold sprayed copper and aluminum.
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