OpenColdSpray

Cold spray repair parameter selection

OpenColdSpray is a free engineering tool for deciding whether a damaged metal part can be repaired by cold spray, and for recording the reasoning behind that decision. It calculates the deposition window from the process parameters you actually use, shows how reliable that window is once real process variation is included, and assembles the result into a signed and sealed repair case file.

What it calculates

  • Deposition window. Particle velocity against critical velocity for your powder, substrate, carrier gas and equipment, expressed as a velocity ratio.
  • Bonding probability. Monte Carlo propagation of your process tolerances, giving the probability of bonding rather than a single number, and a ranking of which tolerance drives the spread.
  • Blend-out geometry. Stress concentration factor for the excavated defect, screened against proceed and re-prepare thresholds.
  • Fatigue life. Comparison of repaired against unrepaired life using a Paris-law treatment of the stress concentration.
  • Deposition efficiency. Measured efficiency and deposition rate from coupon mass balance, benchmarked against typical bands.
  • Cost per part. Gas, powder, labour and machine time broken down.
  • Machine learning. Cross-validated models fitted to your own experimental data, with permutation importance.

Model provenance

Every correlation is recorded with its published source and the range of conditions over which that source validated it. Results computed outside that range are still shown, but flagged as extrapolated, so it is clear when a number is no longer supported by the underlying data.

Repair case file

Inputs as entered, results, model sources and validity ranges, assumptions, inspection plan and a sign-off block, issued as a single PDF with a SHA-256 integrity digest and a companion data file so the document can be verified later.

Start with parameter selection · Read the user guide · Scope, validation and privacy

All results are engineering screening calculations. Qualification and structural disposition remain the responsibility of an authorised engineer working to the governing specification.