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the cold spray technology uses no gasses or lasers and unlike laser welding is non-contact. it is a powder material which is fired at high velocity upon the target surface which is bombarded with tiny particles or specks of a compressed gas. the gas particle expands at the surface increasing the surface temperature to molten and welds the surfaces together. the cold spray powder consists of aluminium, nickel, and chromium li et al., 20139 li m, chen d, zhang s, tong j (2013) biomimetic design of a stubble-cutting disc using finite element analysis. journal of bionic engineering 10(1):118127. doi:
which forms an alloy, as does the weld. these alloys are brittle allowing significant reductions in thickness with increased strength. the cost of cold spray materials are also very low while the process is environmentally friendly and not hazardous. it is being used extensively in the aviation industry for the manufacture of airframe structures and is also being applied in the automotive and naval shipbuilding industries.

a number of studies have already confirmed the efficiency of cold spray technology in welding automotive systems. in their study they (wang et al., 2016) confirmed that cold spray welding was both reliable and time-saving. he also pointed out that cold spray welding could potentially replace laser welding which was then used to make the airframe structure.22 they also confirmed that cold spray was as effective as conventional welding in three hours, when the cold spray temperature reached 1,200° c. they even concluded that cold spray was as effective as laser welding in two hours, when the cold spray temperature was 750° c. oksuz et al., 201825 oksuz f, bucak a, yilmaz e, barisoglu e, sezer m (2018) design of composite feedstock and manufacturing process to produce high strength aerospace grade welds by cold spraying. international journal of materials and production 6(1):46-52. doi:
in the recent past hot gas assisted laser welding has been in use and is being used for the manufacture of rocket parts and other aircraft components. however cold spray welding has the potential to replace hot gas assisted laser welding. the most important advantage of cold spray is that its process can reduce the number of operations by about 70 to 80%. cold spray welding is also more cost-effective than hot gas laser welding which is used in the aerospace industry for making the manufacturing of aircraft parts. therefore, cold spray has the potential to be a substitute for hot gas assisted laser welding.


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