In analysis, the fine powder spray achieved an efficiency of 33%, with the coarse powder achieving 31%. An examination of surface morphology showed that the cold spray coatings also had smoother surfaces than those coated through LPPS. As this was a limited study, results demonstrated no obvious correlation between powder particle size distribution, deposit efficiency and coating microstructure over the study range. However, the coating evolution study, coating degradation through testing in static air at high temperature, and coating consumption when compared with a VPS coating of the same composition, showed the cold spray process to be a more robust, longer-lasting alternative for the company.
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