Cold spray (CS) has seen an emerging role in repair applications. Despite its advantages, the structural integrity of CS repaired materials remains a concern due to the porosity, poor inter-particle bonding, and lack of data.
In this study, the mechanical performance of CS repaired samples under static and cyclic loading is investigated. Different powder heat-treatment conditions and repair geometries are used to improve the deposition performance and structural integrity.
Under tensile loading, the CS repair failed and started delaminating at around 1% elongation, whereas the specimens continued carrying tensile loading up to 7% elongation before the complete fracture, which is 50% less than the wrought material performance. Conversely, the high cycle fatigue life of the repaired samples is similar to the wrought ones, exceeding 10 million cycles at 200MPa. The common observation for all samples was the fatigue crack initiated at the interface and propagated towards the substrate.