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<p>Low-pressure cold spray (LPCS) is an advanced solid-state surface coating technique used for depositing functional coatings and repairing worn-out components. However, low operating pressure and temperature often result in poor deposition efficiency and suboptimal mechanical properties. This study optimizes toolpath strategies to enhance deposition efficiency, coating thickness, and wear resistance in LPCS coatings. Al + Al<sub>2</sub>O<sub>3</sub> composite coatings were deposited on low-carbon steel substrates following various toolpath strategies: zigzag and spiral. Coating characterization studies revealed that samples deposited using spiral toolpath have exhibited superior deposition characteristics. Spiral toolpath strategy has resulted in 5% higher deposition efficiency and 12% greater coating thickness compared to Zigzag. Further studies based on simulation revealed that spiral strategy ensured uniform heat distribution with higher average surface temperatures contributing to better particle adhesion and coating density. Microstructural characterization confirmed that all coatings were free from cracks and layer delamination, with a strong bonding at substrate-coating interface. Tribology studies showed that samples deposited <i>via</i>. Spiral toolpath were exhibiting greater wear resistance than the samples that are deposited following zigzag strategy. These findings establish that toolpath optimization is crucial for coating performance in surface coatings, repair, and remanufacturing applications.</p>

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Enhancing Wear Resistance and Deposition Efficiency in Low-Pressure Cold Spray Coatings through Toolpath Optimization

  • 期刊论文

  • 发表日期：

    2026年2月4日

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  • Chaitanya Gullipalli,
  • Kesavan Ravi

摘要

Low-pressure cold spray (LPCS) is an advanced solid-state surface coating technique used for depositing functional coatings and repairing worn-out components. However, low operating pressure and temperature often result in poor deposition efficiency and suboptimal mechanical properties. This study optimizes toolpath strategies to enhance deposition efficiency, coating thickness, and wear resistance in LPCS coatings. Al + Al2O3 composite coatings were deposited on low-carbon steel substrates following various toolpath strategies: zigzag and spiral. Coating characterization studies revealed that samples deposited using spiral toolpath have exhibited superior deposition characteristics. Spiral toolpath strategy has resulted in 5% higher deposition efficiency and 12% greater coating thickness compared to Zigzag. Further studies based on simulation revealed that spiral strategy ensured uniform heat distribution with higher average surface temperatures contributing to better particle adhesion and coating density. Microstructural characterization confirmed that all coatings were free from cracks and layer delamination, with a strong bonding at substrate-coating interface. Tribology studies showed that samples deposited via. Spiral toolpath were exhibiting greater wear resistance than the samples that are deposited following zigzag strategy. These findings establish that toolpath optimization is crucial for coating performance in surface coatings, repair, and remanufacturing applications.