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Cold spray (CS) is a new kind of coating that has many potential uses, including functionalizing surfaces, doing localized repairs, and mass production. Its fast deposition rate and diverse feedstocks have led to its growing popularity as an additive manufacturing method, which has been driven by improvements in lateral resolution. CS materials have several uses in the transportation industry, and some of the most frequent ones include nickel super-alloys, titanium alloys, copper, aluminum and metal-ceramic composites. Nevertheless, the mechanical properties depend upon number of parameters involved during spraying process. Therefore, there is an immediate need for researchers and businesses to understand the various parameters affecting the adhesion strength of CS deposits. The current research presents an analysis of the adhesion behavior of coatings that have been deposited by CS methodology.

In 21st century with the advent of industrial revolution 4.0, the future manufacturing and power generation industries will scale new heights. The focus of researchers and engineers is on higher operating plant/gas turbine temperatures and more efficient plants with minimal breakdowns. This is possible practically due to the development of new heat/corrosion/erosion resistant materials using different surface engineering approaches. The main focus of this article is to review the solid particle erosion behavior of conventional, nano materials and high entropy alloys under elevated temperatures and the summarized analysis helps the researchers in selecting the appropriate composition, coating methods and erosion resistant materials to combat the erosion at elevated temperatures, so that life of components can be improved. In addition to this future perspective is also discussed.

Cold spray processing (CS) is an all-solid-state, relatively low-temperature coating method that overcomes the drawbacks of traditional thermal spray methods to enable the spraying of heat and O2-sensitive materials. Defects like phase change, residual stresses and de-bonding are typical when conventional coating methods such as plasma spray for deposition of biomaterials. This review sums up the restrictive method CS used for depositing biomaterials at low temperatures which restricts the formation of oxides; minimize phase changes and introduce compressive residual stresses. Due to these benefits it appears to be on the verge of being competitive with other conventional approaches. The CS technique contributes to improve bioactivity, corrosion resistance, wear resistance and preserve the properties of biomaterials. We attempt to provide a succinct and thorough overview of biomaterials which can be fabricated using CS.

The standard method for applying hydroxyapatite (HAP) coatings to biomedical implants is plasma spraying. However, due to the high temperature of the plasma, these coatings frequently experience negative effects like evaporation, phase change, de-bonding, gas release, and residual stresses. This paper summarizes a revolutionary technique known as a cold spray (CS), which allows HAP coatings to be applied at temperatures well below their melting point. CS has several advantages over conventional high-temperature technologies, and it seems to be approaching parity with other older methods. When applied using the CS approach, the HAP coatings enhance bioactivity, increase corrosion resistance, and main­tain the characteristics of calcium phosphate ceramics. This study aims to give a concise and comprehensive overview of HAP-based materials, including substituted-HAP and HAP/poly­mer composites, and their applications in bone tissue engineering. To better understand the advantages of CS technology, a comparison of CS, high-velocity oxy-fuel (HVOF), and plasma spray is given at the end. The perspective and difficulties were also highlighted.