Parameters and Process Interactions in Laser-Assisted Cold Spray

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Maximilian Mosig, mosigm@hsu-hh.de; Merlin Klutta, jim.klutta@hsu.hamburg.de; 

The conventional cold spray process is often limited by insufficient bonding strength, primarily due to limited heat input to achieve adequate deposition conditions. Laser-assisted cold spraying enables the localized input of additional thermal energy into the substrate surface during deposition, aiming to reduce temperature gradients and improve coating quality. However, the relationship between process parameters and the resulting coating properties is complex. Furthermore, additional heat input by the laser depends on laser light absorption, which differs for different materials and surface roughness also light may be scattered by the particles in flight. Therefore, laser intensity has to be tuned and controlled carefully. This paper reviews data from literature and recent studies to identify relevant parameters and to examine their interdependencies in laser-assisted cold spray processes. The Data are subsequently clustered based on their functional roles and process-related effects of individual parameters. The goal is to provide a comprehensive overview of critical interactions and recurring patterns. This paper finally identifies future research needs for systematic process control and optimization, with particular emphasis on trajectory planning to ensure reproducible thermal input.

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Erscheinungsdatum

March 2026

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