Low-pressure cold spray (LPCS) technology has attracted interest for the deposition of ceramic coatings due to the thermo-kinetic conditions experienced by the sprayed particles. Unlike conventional thermal spray techniques, the spraying conditions in LPCS can be controlled to avoid the formation of undesired phases. However, ceramics deposition through this process is still challenging. The present study includes a finite element analysis and simulation study of the kinetic conditions of ceramic particles in the LPCS process based on experimental data. The analysis seeks to discuss the effect of nozzle geometry on the kinetic and thermal energy of the sprayed particles at impact and elucidate how the particle travels within the high-velocity jet to be deposited onto a metallic surface. This work examines the behavior of hydroxyapatite particles as a function of particle size and nozzle geometry during LPCS deposition. Interestingly, the results from this research suggest that particle size and nozzle geometry have an influence on the deposition of hydroxyapatite particles. Inertia of large particles proved to be beneficial in keeping their trajectories, allowing them to contribute to the formation of the coatings. Nozzle geometry modifications produced changes in the jet profile and affected the homogeneity of the coatings obtained. This finding contributes to a better understanding of the deposition of hydroxyapatite particles by cold spraying.

The manufacture of cellular structures using high-performance materials is possible thanks to the additive manufacturing of metals. However, it is well known that the mechanical and microstructural properties of metals manufactured by this technique do not correspond to those of the same metals manufactured by conventional methods. It is well known that the mechanical properties depend on the direction of manufacture, the size of the pieces, and the type of cell structure used. In addition, the effect of heat treatments on parts manufactured by additive manufacturing differs from parts manufactured by conventional methods. In this work, the microstructure and microhardness of cellular structures of Inconel 718, manufactured by additive manufacturing under heat treatments with different aging times, were evaluated. It was found that the time of the first aging impacts the microhardness and its homogeneity, affecting the microstructure. The highest hardness was obtained for an aging time of 8 h, while the lowest standard deviation was obtained at 10 h. Finally, it is shown that the aging time influences a more homogeneous distribution of the elements and phases.

The deposition of agglomerated hydroxyapatite (HAp) powders by low-pressure cold spray has been a topic of interest in recent years. Key parameters influencing the deposition of HAp powders include particle morphology and impact kinetic energy. This work examines the deposition of HAp powders on various metal surfaces to assess the impact of substrate properties on the formation of HAp deposits via cold spray. The substrates studied here encompass metals with varying hardness and thermal conductivities, including Al6061, Inconel alloy 625, AISI 316 stainless steel, H13 tool steel, Ti6Al4V, and AZ31 alloy. Single-track experiments offer insights into the initial interactions between HAp particles and different substrate surfaces. In this study, the results indicate that the ductility of the substrate may enhance HAp particle deposition only at the first deposition stages where substrate/particle interaction is the most critical factor for deposition. Features on the substrate associated with the first deposition sprayed layer include localized substrate deformation and the formation of clusters of HAp agglomerates, which aid in HAp deposition. Furthermore, after multiple spraying passes on the various metallic surfaces, deposition efficiency was significantly reduced when the build-up process of HAp coatings shifted from ceramic/metal to ceramic/ceramic interactions. Overall, this study achieved agglomerated HAp deposits with high deposition efficiencies (30–60%) through single-track experiments and resulted in the preparation of HAp coatings on various substrates with thickness values ranging from 24 to 53 µm. These coatings exhibited bioactive behavior in simulated body fluid.

The mechanical behaviour of a DMLS Ti-6Al-4V gyroid-based cellular structure (CS), with potential application in the fabrication of implants, was studied under compressive conditions. The influence of the CS volumetric fraction on the elastic modulus was experimentally evaluated in cubic and cylindrical samples. The experimental results showed that the selected parameters allowed approximating the mechanical behaviour of the CS to that of trabecular bone. Finite element analysis was employed to study the mechanical behaviour of the CS. The model presented a good approximation of the experimental results, being useful to predict the mechanical behaviour of the CS.