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1. (WO2019008405) A METALLIC SUBSTRATE BEARING A COLD SPRAYED COATING
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Claims

1. A metallic substrate bearing a cold sprayed coating comprising:

- from 1.0 to 10.0% by weight of zinc,

- optionally less than 20% by weight of Al203,

- the balance being aluminum,

- said coating having a porosity between 0.9 and 8.0% and

- wherein the microstructure of the coating does not comprise an

intermetallic diffusion layer made of Fe and Al.

2. A metallic substrate bearing a cold sprayed coating according to claim 1 , wherein the coating comprises from 2.0 to 8.0% by weight of zinc.

3. A metallic substrate bearing a cold sprayed coating according to claim 2, wherein the coating comprises from 3.0 to 6.0% by weight of zinc.

4. A metallic substrate bearing a cold sprayed coating according to anyone of claims 1 to 3, wherein the coating comprises between 10 and 20% by weight of Al203.

5. A metallic substrate bearing a cold sprayed coating according to anyone of claims 1 to 4, wherein the coating has a porosity between 3.0 and 7.0%.

6. A metallic substrate bearing a cold sprayed coating according to anyone of claims 1 to 5, wherein the microstructure of the coating does not comprise an intermetallic diffusion layer.

7. A metallic substrate bearing a cold sprayed coating according to anyone of claims 1 to 6, the coating does not comprise at least one of the following elements: AI2O3 and magnesium.

8. A metallic substrate bearing a cold sprayed coating according to anyone of claims 1 to 7, wherein the thickness of the coating is between 100 and 350μηι.

9. A metallic substrate bearing a cold sprayed coating according to anyone of claims 1 to 8, wherein the coating hardness is between 40 and 80 HV(0.1).

10. A metallic substrate bearing a cold sprayed coating to anyone of claims 1 to 9, wherein the metallic substrate is chosen among: aluminum substrate, steel substrate, stainless steel substrate, copper substrate, iron substrate, copper alloys substrate, titanium substrate, cobalt substrate or nickel substrate.

1 . A metallic substrate bearing a cold sprayed coating according to claims 1 to 10, wherein the metallic substrate is a part chosen from: a piling, a wire, a plate, a tube and a beam.

12. A method for the manufacture of a metallic substrate bearing a cold sprayed coating comprising the following step:

A. The provision of a metallic substrate,

B. Optionally, a surface preparation step of the metallic substrate,

C. The cold spray deposition of a powder mixture, comprising from 1.0 to 10.0% by weight of zinc, optionally less than 20% by weight of AI2O3, the balance being aluminum, on a metallic substrate, said deposition being performed in a cold spray device comprising a heating section, a powder feeder and a supersonic nozzle.

13. A method according to anyone of claim 13, wherein step C) comprises the following sub-steps:

vi. The injection of at least one gas in the cold spray device, said gas being under pressure,

vii. The heat treatment of a first part of the gas at a temperature between 200 and 600°C in a heating section, viii. the transport of the second part of the gas through the powder feeder section so as to carrier the powder mixture,

IX. The mixing of the first and the second parts of gas before the ejector of the supersonic nozzle and

x. The acceleration of the mixing gases comprising the powder mixture at supersonic speed through the ejector of the supersonic nozzle so as to deposit the powder mixer on the metallic substrate.

14. Method according to claim 12 or 13, wherein when step B) is performed, the surface treatment is chosen from: shot blasting, pickling polishing, sand blasting and grinding.

15. Method according to 12 to 14, wherein in step C.i), the gas is chosen among: nitrogen, argon, helium, air or a mixture thereof.

16. Method according to anyone of claims 12 to 15, wherein in step C.i), the pressure of the gas is between 1 and 10 MPa.

17. Method according to anyone of claims 12 to 16, wherein in step C.ii), the first part represents above 60% by volume of the gas and the second part represents below 40% by volume of the gas.

18. Method according to anyone of claims 12 to 17, wherein in step C.v), the supersonic speed is between 350 and 1200m.s"1.

19. Method according to anyone of claims 12 to 18, wherein in step C.v), the distance projection between the ejector supersonic and the metallic substrate is between 10 and 50mm.

20. Method according to anyone of claims 12 to 19, wherein in step C.v), the projection angle between the ejector supersonic and the metallic substrate is between 70 and 1 10°.

21. Method according to anyone of claims 12 to 20, wherein the powder mixture shape is spherical, spheroidal or angular.

22. Method according to anyone of claims 12 to 21 , wherein the powder mixture has a size above 10μιη.

23. Method according to anyone of claims 12 to 22, wherein the hardness of the powder mixer is between 30 and 50HV (0.01 ).

24. Use of a metallic substrate bearing a cold sprayed coating according to anyone of claims 1 to 1 1 or obtainable according to anyone of claims 12 to 23, for the manufacture of offshore structure, Offshore wind power, Marine current power, hull of a boat, coastal and port infrastructure, quay wall and, underground structure, rail and anchorage.