Cold spray coatings elaboration requires optimization of numerous parameters in order to reach the best coatings' performances. A systematic approach can be avoided by using an experimental design. A Doehlert uniform shell design was applied in this work to Zn cold sprayed coating. Coatings were produced on steel substrates to provide high corrosion resistant layers. N₂ temperature and gas pressures varied from 200 °C to 320 °C and from 2.0 MPa to 3.0 MPa, respectively. Performance maps were plotted for two descriptors: (i) the interfacial porosity volume (substrate coating interface defects), (ii) coating thickness (i.e., coating durability), and validated with the polarization resistance (i.e., corrosion resistance). Results reported three set of optimized temperature and gas pressure values according to the descriptor.

Two optimized protection modes can be obtained: a sacrificial mode from heterogeneities in the coating (290 °C and 3.0 MPa), and a barrier protection mode from homogeneous and dense coatings (320 °C and 2.5 MPa). Mechanism of corrosion has been investigated.

冷喷涂涂层的精加工需要优化许多参数，以达到最佳涂层性能。通过使用实验设计可以避免系统的方法。在这项工作中，将Doehlert均匀外壳设计应用于Zn冷喷涂涂层。在钢基材上生产涂层以提供高耐腐蚀层。N ₂温度和气压分别在200°C至320°C和2.0 MPa至3.0 MPa之间变化。绘制了两个描述符的性能图：（i）界面孔隙体积（基材涂层界面缺陷），（ii）涂层厚度（即涂层耐用性），并用抗极化性（即耐腐蚀性）验证。结果根据描述报告了三组优化的温度和气压值。

可以得到两种优化的保护模式：一种基于涂层异质性的牺牲模式（290°C和3.0 MPa），以及一种针对均质和致密涂层的阻挡层保护模式（320°C和2.5 MPa）。已经研究了腐蚀机理。