Cold spraying, an advanced technology based on solid-state deposition, utilizes supersonic airflow to accelerate metal powder particles, causing them to bond firmly to the substrate or existing deposited layers through intense plastic deformation in a solid state, thus building up a dense structure layer by layer. The greatest advantage of this process lies in its low-temperature characteristics, completely avoiding problems such as heat-affected zones, phase transformations, oxidation, and cracking caused by material melting. It is particularly suitable for processing heat-sensitive high-performance aerospace materials such as aluminum alloys and titanium alloys. Its applications have expanded from traditional surface coating engineering to high-performance additive manufacturing that can directly produce near-net-shape solid components, as well as remanufacturing and repair. In the field of low-cost aerospace repair manufacturing, this technology provides a revolutionary solution for the repair of wear, corrosion, and damage to expensive critical components such as engine blades, casings, and gearboxes. It not only achieves precise dimensional restoration and performance recovery of components but also significantly extends component life, reduces spare parts costs and maintenance cycles. Its relatively flexible equipment also possesses the potential for rapid on-site emergency repair. Despite challenges in deposition efficiency, accessibility to complex structures, and standardization, cold spraying is becoming a key technology driving high performance, green remanufacturing, and life-cycle cost control for aerospace equipment, thanks to advancements in robotic integration, online monitoring, and post-processing technologies.

cold spray, additive manufacturing, repair