Supersonic Cold Spraying for Energy and Environmental Applications: One-Step Scalable Coating Technology for Advanced Micro- and Nanotextured Materials

Seongpil An, Bhavana Joshi, Alexander L. Yarin, Mark T. Swihart, Sam S. Yoon

Research output: Contribution to journalReview article

1 Citation (Scopus)


Supersonic cold spraying is an emerging technique for rapid deposition of films of materials including micrometer-size and sub-micrometer metal particles, nanoscale ceramic particles, clays, polymers, hybrid materials composed of polymers and particulates, reduced graphene oxide (rGO), and metal–organic frameworks. In this method, particles are accelerated to a high velocity and then impact a substrate at near ambient temperature, where dissipation of their kinetic energy produces strong adhesion. Here, recent progress in fundamentals and applications of cold spraying is reviewed. High-velocity impact with the substrate results in significant deformation, which not only produces adhesion, but can change the particles' internal structure. Cold-sprayed coatings can also exhibit micro- and nanotextured morphologies not achievable by other means. Suspending micro- or nanoparticles in a liquid and cold-spraying the suspension produces fine atomization and even deposition of materials that could not otherwise be processed. The scalability and low cost of this method and its compatibility with roll-to-roll processing make it promising for many applications, including ultrathin flexible materials, solar cells, touch-screen panels, nanotextured surfaces for enhanced heat transfer, thermal and electrical insulation films, transparent conductive films, materials for energy storage (e.g., Li-ion battery electrodes), heaters, sensors, photoelectrodes for water splitting, water purification membranes, and self-cleaning films.

Original languageEnglish
Article number1905028
JournalAdvanced Materials
Issue number2
Publication statusPublished - 2020 Jan 1



  • energy and environmental applications
  • low-cost coating
  • multidimensional nanomaterial deposition
  • scalable nonvacuum coating
  • supersonic cold spraying
  • ultrathin flexible materials

ASJC Scopus subject areas

  • Materials Science(all)
  • Mechanics of Materials
  • Mechanical Engineering

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