Tailoring microstructure and enhancing Interfacial Bonding of Cold Spray- Coatings Through a Novel Induction-Based In-Situ Powder Preheating Technique

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PhD Candidate Hamid Rahmati, hamid.rahmati@uottawa.ca, University of Ottawa; Prof. Patrick Richter, Patrick.Richer@uottawa.ca, University of Ottawa; Prof. Bertrand Jodoin, Bertrand.Jodoin@uottawa.ca, University of Ottawa; 
Assistant Professor Aleksandra Nastic, aleksandra.Nastic@uottawa.ca, University of Ottawa; Prof. Hamid Jahed Motlagh, hamid.jahed@uwaterloo.ca, University of Waterloo; CEO Luc Pouliot, luc.pouliot@polycontrols.com, Polycontrols Technologies Brossard; Julia Villafuerte, Murray Pearson;

A novel in-situ compact powder preheater that integrates seamlessly with existing cold spray (CS) technology is proposed. It is designed to enhance the CS process performance for materials that are challenging to spray due to insufficient ductility at the typical particle impact temperature and velocity experienced in CS. The system was designed using a coupled magnetic/CFD model to tailor the utilized induction heating process. 
Duplex 2205 powder in as-received (D2205A) and sieved (< 25µm) (D2205S) conditions were sprayed using high pressure cold spray (HPCS), low pressure cold spray (LPCS) and LPCS with the proposed preheater system. Particle preheating and impact temperatures were assessed through validated numerical modelling and experimental measurements using a FAST sHD thermographic camera (M3Shd) for the LPCS with preheating system. Coatings’ microstructural characterization was performed for various particle preheating temperatures. The results of this study provide new insights on the effect of particle impact temperature in CS.

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March 2026

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