Abstract
The effect of the substrate surface pretreatment on the Ni–Al interfacial bonding features in cold spray was investigated. Oxide-free interfacial area is found to be the essential factor that affects the interfacial atomic diffusion and metallurgical bonding. Voids are formed at the interface between the particle and grit-blasted substrates, significantly reducing the oxide-free interfacial area. However, those voids cannot be found at the interface between the particle and polished and ground substrates. Therefore, the polished and ground substrates can provide higher coating mass and coating-substrate bonding strength than the grit-blasted ones.
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