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Access Type

Open Access Thesis

Document Type


Degree Program

Mechanical Engineering

Degree Type

Master of Science (M.S.)

Year Degree Awarded


Month Degree Awarded



When a solid, ductile particle impacts a substrate at sufficient velocity, the resulting heat, pressure, and plastic deformation can produce bonding at the interface. The use of a supersonic gas flow to accelerate such particles is known as Cold Spray deposition. The Cold Spray process has been commercialized for some metallic materials, but further research is required to unlock the exciting material properties possible with polymeric compounds. In this work, a combined computational and experimental study a) simulated and optimized the nozzle flow conditions necessary to produce bonding in a polyethylene particle, b) developed and fabricated an experimental device, and c) explored temperature-pressure space across a range of substrate materials, resolving a material dependent ‘window of deposition’ where successful coatings form. Insights into bonding mechanisms are discussed, and paths forward proposed.


First Advisor

Jonathan P. Rothstein

Second Advisor

David P. Schmidt

Third Advisor

Jae-Hwang Lee