Cold spray (CS) has been proven a promising manufacturing process for the MCrAlY coatings deposition. In this study, NiCoCrAlTaY coatings were deposited on single-crystal nickel-based superalloy (CMSX-4) substrates using the CS technique. Nitrogen and moderate spray parameters were used, and the resulting MCrAlY coatings were compared to coatings sprayed using helium under similar spray conditions. It was found that, contrary to general expectation, favorable coating characteristics were achieved when nitrogen was used. This is attributed to low deposition efficiency under the studied spray conditions, resulting in significant particle impingement that promotes overall particle deformation in the coatings sprayed using nitrogen. However, low deposition efficiency may lead to elevated process cost, despite great gas cost savings by using nitrogen, due to significant increases in powder waste and cost. As such, recycling of the non-deposited powder was explored in an aim to reduce powder cost when using nitrogen. A general cost model that considers the benefits of powder recycling was proposed for the CS process. It was demonstrated that the use of nitrogen and powder recycling can be economical over CS using helium, while producing MCrAlY coatings with desirable properties that are potentially beneficial to the oxidation performance of the coatings.

中文翻译：

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使用氮在单晶高温合金上冷喷涂 MCrAlY 涂层：性能和经济性

冷喷涂 (CS) 已被证明是一种很有前途的 MCrAlY 涂层沉积制造工艺。在这项研究中，NiCoCrAlTaY 涂层使用 CS 技术沉积在单晶镍基高温合金 (CMSX-4) 基材上。使用氮气和中等喷涂参数，并将所得 MCrAlY 涂层与在类似喷涂条件下使用氦气喷涂的涂层进行比较。发现与一般预期相反，当使用氮气时实现了有利的涂层特性。这是由于在所研究的喷涂条件下沉积效率低，导致显着的颗粒撞击，从而促进了使用氮气喷涂的涂层中的整体颗粒变形。然而，低沉积效率可能会导致工艺成本升高，尽管使用氮气可以节省大量气体成本，由于粉末浪费和成本的显着增加。因此，为了在使用氮气时降低粉末成本，探索了未沉积粉末的回收利用。针对 CS 工艺提出了一种考虑粉末回收益处的通用成本模型。结果表明，使用氮气和粉末回收比使用氦气的 CS 更经济，同时生产具有所需性能的 MCrAlY 涂层，这些性能可能有利于涂层的氧化性能。