Cold spray is an advanced 3D technique to build thick coatings using ductile powders. Plastic deformations and physical interactions induced by kinetic energy are mainly the origins of interparticle and particle–substrate adhesion. The deposition efficiency, i.e., the quantity of matter deposited compared to the amount propelled, is directly linked to the parameters used in the cold spray. To improve this aspect, parameters’ optimization is also required with other solutions such as using thermally treated powders or powder blending with hard particles. Another approach is recycling powder, though it has not yet been widely evaluated. When depositing a blend of fresh and recycled Sn powder, the results showed improved coating deposition efficiency compared to a batch of 100% fresh or recycled particles. This blend does not significantly change the coating thickness, although it decreases the porosity ratio because of the thermal–mechanical history of the recycled particles. Recycled particles present lower elastic modulus. Finally, coating/substrate adhesion force was unchanged for the blend of fresh and recycled particles, but this still depends on the nature of the powder used.

冷喷涂是一种先进的 3D 技术，可使用延展性粉末构建厚涂层。由动能引起的塑性变形和物理相互作用主要是颗粒间和颗粒-基材粘附的起源。沉积效率，即沉积的物质量与推进量的比较，与冷喷涂中使用的参数直接相关。为了改善这方面，还需要使用其他解决方案来优化参数，例如使用热处理粉末或与硬颗粒混合的粉末。另一种方法是回收粉末，尽管尚未得到广泛评估。当沉积新鲜和回收的 Sn 粉末的混合物时，结果表明，与一批 100% 新鲜或回收的颗粒相比，涂层沉积效率有所提高。这种混合物不会显着改变涂层厚度，尽管由于回收颗粒的热机械历史，它会降低孔隙率。回收的颗粒具有较低的弹性模量。最后，新鲜和回收颗粒的混合物的涂层/基材粘附力没有变化，但这仍然取决于所用粉末的性质。