PetroStreet

I don't know weather you know people of this methord or not it was certainly new for me attached below is the document for reference.

What are the major applications of cold spraying? Non-pressure components only?

No the main application of this method is for repairing pressurized components. I came across this method when I was searching for means to repair a cracked body of a compressor. I have been told (have not been able to verify) that this is a GE recommended repairing method.

Potential cold spray applications include:
1. Surface coating / corrosion protection
2. Mitigation of oxidation / hot corrosion
3. Wear resistance, erosion resistance
4. Casting repairs / cosmetic repairs

I have seen repairs being carried out on certain pressure containing components, machinery body castings but haven't ever experienced using of cold spraying system for repair of piping / pressure vessels to remove defects.

Few more summarized details.

How it works
Cold Spray materials typically:
1. remain at or near room temperature until impact
2. slam into the substrate at supersonic speeds (500-1 500 metres per second)
3. forms a metallurgical bond
4. do not undergo undesirable chemical changes and stresses.
5. Researchers believe the high velocity impact disrupts thin oxide films on the surface of the particles and substrate. This means their atomic structures come into intimate contact under momentarily high interfacial pressures.

Advantages of Cold Spray include:
1. retaining initial properties of particles
2. depositing oxygen-sensitive materials without vacuum
3. low oxide content
4. high density
5. high thermal and electrical conductivity
6. high hardness and cold work microstructure
7. creating corrosion-resistant coatings
8. depositing plastic coatings without the need for volatile solvents
9. intermetallic coatings or repair (phase and compositional stability)
10. depositing metal on ceramic or metal on glass
11. ability to perform rapid prototyping.

Outcomes
This technology offers the opportunity for:
1. direct fabrication of low-defect parts
2. repairing defective areas without changing the structure
3. joining chemically dissimilar materials with bonds that gradually transition from one material to the other
4. a low-temperature alternative to welding
5. building a composite component using different materials in different locations
6. rapid prototyping.

Applications
Any industry using thermal spray systems could likely use Cold Spray technology.
Examples include:
1. biomedical – prostheses with improved wear
2. aerospace – fatigue-resistant coatings
3. chemical – improved corrosion resistance
4. mineral processing – improved corrosion and erosion resistance
5. die casting – extending die life
6. electronics – creating a heat sink or superconductive, magnestostrictive surfaces
7. printing – copper coating on rollers
8. oil and gas – improved corrosion resistance
9. glass – platinum coating.