Emerging Trends in Cold Spray: Process Evolution and Materials Development

Dear Colleagues,

The continuous evolution of advanced manufacturing has created a growing demand for innovative surface engineering technologies capable of enhancing component performance without compromising material integrity. Among these, cold gas dynamic spray (commonly known as cold spray) has emerged as a versatile solid-state deposition technique, enabling the fabrication of high-quality coatings and repairs while preserving the original microstructure of the feedstock material. This process is particularly well-suited for temperature-sensitive materials and applications requiring high bond strength, wear resistance, or corrosion protection.

This Special Issue is dedicated to showcasing recent progress and addressing current challenges in cold spray research and applications. It aims to bring together contributions that advance our understanding of process fundamentals, materials behavior, and performance optimization. Topics of interest include, but are not limited to, the following:

• Innovations in cold spray system design and process optimization;
• Development of novel feedstock materials and tailored substrates;
• Integration of cold spray in additive manufacturing and repair strategies;
• Coating–substrate bonding mechanisms and interfacial phenomena;
• In situ diagnostics and real-time process monitoring;
• Industrial case studies and application-driven developments.

Through this collection, we seek to highlight cutting-edge research that pushes the boundaries of cold spray technology and fosters its broader adoption across industries.

Dr. Alessia Serena Perna
Guest Editor

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