Influence of primary and secondary parameters on the corrosion behavior of cold sprayed Inconel®625 deposits

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Dr.-Ing. Farrokh Taherkhani, Helmut Schmidt University University of the Federal Armed Forces Hamburg; Frank Gärtner, gaertner@hsu-hh.de, Institute of Materials Technology, Helmut Schmidt University / UniBwH; Prof. Dr.-Ing. Max Gündel, max.guendel@hsu-hh.de, Chair of Steel Structures, Helmut Schmidt University / UniBw H; Prof. Dr.-Ing. Zhomas Klassen, klassen@hsu-hh.de, Institute of Materials Technology, Helmut Schmidt University / UniBw H;

https://doi.org/10.53192/ITSC2026521

Owing to its high chromium content, Inconel®625 is widely used as protective coating to withstand corrosion at high-temperature and aggressive environments. To prevent oxidation, solid state deposition by cold spraying offers advantages for building-up of coatings up to several millimetres in thickness compared to conventional thermal deposition processes. However, cold spraying of Inconel®625 remains still challenging due to its high strength. For potential applications in harsh environments, this study examines how cold spray parameter sets influence the extent of non-bonded interfaces, which consequently determine the achievable corrosion resistance. This study evaluates corrosion performance using open-circuit potential (OCP) testing and salt spray measurement. The results indicate that achieving lower porosity in cold sprayed coatings requires both adjustment of spray parameters to improve coating quality parameter (η) and optimization of robot kinematics. Consequently, enhanced primary parameter sets improve corrosion resistance. In addition to the primary parameter sets, the results demonstrate that corrosion resistance is improved by higher surface temperatures, which are generated using lower traverse velocities or shorter standoff distances. Overall, the findings identify the key conditions to achieve deposit qualities capable of performing under extreme environmental conditions.

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Erscheinungsdatum

March 2026

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