Novel cryogenic powder injection for improved coating quality by cold spraying of Al6061

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M. Sc. Sören Nielsen, nielsens@hsu-hh.de, Helmut-Schmidt-Universität Hamburg; Luca klingler, luca.klingler@hsu-hh.de, Helmut Schmidt University Hamburg; M. Sc. Maximilian Mosig, mosigm@hsu-hh.de, Helmut Schmidt University Hamburg; Dr. Alexander List, a.list@hsu-hh.de, Helmut Schmidt University Hamburg; Dr. Frank Gärtner, gaertner@hsu-hh.de, Helmut Schmidt University Hamburg; Prof. Thomas Klassen, klassen@hsu-hh.de, Helmut Schmidt University Hamburg; 

Achieving bulk-like properties for cold-sprayed Al6061 with nitrogen as a propellant remains challenging. In this study, the thermo-mechanical response of Al6061 particles during impact is systematically studied by controlling in-flight thermal conditions. A novel cryogenic carrier gas cooling device employing liquid nitrogen as coolant was used to reduce the particle injection temperature. Additionally, the in-flight heating time was adjusted by varying the injection distance. The resulting coating properties were evaluated with respect to deformation, microstructures and mechanical deposit performance. It is shown that applying the coldest particle impact temperatures lead to a low porosity of 0.5 % as well as the best deposit properties with a tensile strength of 273 MPa and a strain to failure of 0.75 %. These results are explained in terms of a thermo-mechanical framework thereby considering adiabatic shear localization on particle and surface sites as well as enhanced peening effects. Apart from that, also effects of in-flight particle heating are evaluated in view of in-situ particle aging.

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March 2026

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