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Cold spraying superalloys:research status,challenges and perspectives
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Wenya LI1, 2, Gefei WU1, 2, Yuhan LI1, 2, Yaxin XU1, 2, Chunjie HUANG1, 2, Xiaotao LUO3, Yingchun XIE4, Shuo YIN5
Journal of Materials Engineering | 2025, 53(12) : 1 - 13
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Journal of Materials Engineering | 2025, 53(12): 1-13
• ADVANCED COLD SPRAYING TECHNOLOGY COLUMN •
Cold spraying superalloys:research status,challenges and perspectives
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Wenya LI1, 2, Gefei WU1, 2, Yuhan LI1, 2, Yaxin XU1, 2, Chunjie HUANG1, 2, Xiaotao LUO3, Yingchun XIE4, Shuo YIN5
Affiliations
  • 1.State Key Laboratory of Solidification Processing,School of Materials Science and Engineering,Northwestern Polytechnical University,Xi’an 710072,China
  • 2.Shaanxi Key Laboratory of Friction Welding Technologies,School of Materials Science and Engineering,Northwestern Polytechnical University,Xi’an 710072,China
  • 3.School of Materials Science and Engineering,Xi’an Jiaotong University,Xi’an 710049,China
  • 4.School of Space Science and Technology,Shandong University,Weihai 264209,Shandong,China
  • 5.Department of Mechanical,Manufacturing and Biomedical Engineering,Trinity College Dublin,University of Dublin,Dublin D02 PN40,Ireland
Published: 2025-12-20 doi: 10.11868/j.issn.1001-4381.2025.000488
Outline
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Cold spraying technology has a number of unique characteristics, most notably the solid-state metal powder deposition. This property confers the technology with significant technical advantages and application potentials in the domains of coating preparation, high-efficiency and high-speed repair, and additive manufacturing. Nevertheless, when applying for high-strength nickel-based superalloy materials, this technology remains confronted with significant technical challenges, including high coating porosity, inadequate strength, and an absence of plasticity. In this paper, the critical deposition conditions and influencing factors of cold-sprayed superalloys are systematically reviewed, focusing on the microstructure characteristics of deposited materials and their correlations with properties (especially tensile properties), and summarizing the main methods of microstructure and performance optimization, such as post-spray heat treatment, post-spray hot isostatic pressing, laser-assisted cold spraying, and in-situ shot peening-assisted cold spray deposition. In the future, for expanding the engineering applications of cold-sprayed high-temperature alloys, it is necessary to modify the particle deformation conditions and expand the deposition window, to develop the hybrid treatment methods to improve the coating property, as well as lowering the process costs. These measures will provide a theoretical basis and technical guidance for its applications in the fields of aerospace.

cold spraying  /  superalloy  /  critical velocity  /  microstructure  /  property  /  damage repair  /  additive manufacturing
李文亚, 吴格飞, 李昱晗, 徐雅欣, 黄春杰, 雒晓涛, 谢迎春, 殷硕. 冷喷涂高温合金:研究现状、挑战与展望. 材料工程, 2025 , 53 (12) : 1 -13 . DOI: 10.11868/j.issn.1001-4381.2025.000488
Wenya LI, Gefei WU, Yuhan LI, Yaxin XU, Chunjie HUANG, Xiaotao LUO, Yingchun XIE, Shuo YIN. Cold spraying superalloys:research status,challenges and perspectives[J]. Journal of Materials Engineering, 2025 , 53 (12) : 1 -13 . DOI: 10.11868/j.issn.1001-4381.2025.000488
Year 2025 volume 53 Issue 12
47
20
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Article Info
doi: 10.11868/j.issn.1001-4381.2025.000488
  • Receive Date:2025-09-01
  • Online Date:2026-10-26
  • Published:2025-12-20
Article Data
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History
  • Received:2025-09-01
  • Accepted:2025-09-18
Funding
Affiliations
    1.State Key Laboratory of Solidification Processing,School of Materials Science and Engineering,Northwestern Polytechnical University,Xi’an 710072,China
    2.Shaanxi Key Laboratory of Friction Welding Technologies,School of Materials Science and Engineering,Northwestern Polytechnical University,Xi’an 710072,China
    3.School of Materials Science and Engineering,Xi’an Jiaotong University,Xi’an 710049,China
    4.School of Space Science and Technology,Shandong University,Weihai 264209,Shandong,China
    5.Department of Mechanical,Manufacturing and Biomedical Engineering,Trinity College Dublin,University of Dublin,Dublin D02 PN40,Ireland
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表12种不同金属材料的力学参数
科
Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)
属
Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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