Influences of spray velocity on surface temperature and deposit properties in cold gas spraying of Al6061

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M.Sc. Luca Klingler, luca.klingler@hsu-hh.de, Helmut-Schmidt-Universität; M. Sc. Maximilian Mosig, mosigm@hsu-hh.de, Helmut-Schmidt-Universität; Dr.-Ing. Alexander List, a.list@hsu-hh.de, Helmut-Schmidt-Universität; Dr. rer. nat. Frank Gärtner, gaertner@hsu-hh.de, Helmut-Schmidt-Universität; Univ.-Prof. Dr.–Ing. habil. Thomas klassen, klassen@hsu-hh.de, Helmut-Schmidt-Universität; 

Achieving desired deposit properties in cold spraying is often only possible by careful tuning of primary and secondary parameters. With respect to secondary parameters, however, a systematic study of the underlying effects, such as surface temperature and heat distribution, is still missing. To provide further insights, this study systematically investigates the influences of the spray velocity, or commonly termed traverse gun velocity, on surface temperature by means of a high-speed infrared camera during cold gas spraying of Al6061 in combination with analyzes of the resulting deposit performance. The deposits were investigated with respect to deposition efficiency, microstructure, porosity, hardness, residual stresses, as well as electrical conductivity and ultimate tensile strength. The results demonstrate a complex interdependence of parameters: e.g., lower spray velocities result in higher surface temperatures, which improves deposit properties, but increases residual stresses. Based on correlations between locally reached surface temperature and the development of the different properties, recipes are derived to provide recommendations for careful tuning and optimum process control to improve deposit performance in cold gas spraying. The better understanding of the role of surface temperature on deposit build-up supports the development of optimum robot trajectories in structural repair and 3D additive manufacturing by cold spraying.

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March 2026

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