Abstract: Large interfacial strains in particles are crucial for promoting bonding in cold spraying (CS), initiated either by adiabatic shear instability (ASI) due to softening prevailing over strain hardening or by hydrostatic plasticity, which is claimed to promote bonding even without ASI. A thorough microstructural analysis is vital to fully understand the bonding mechanisms at play during microparticle impacts and throughout the CS process. In this study, the HEA CoCrFeMnNi, known for its relatively high strain hardening and resistance to softening, was selected to investigate the microstructure characteristics and bonding mechanisms in CS. This study used characterization techniques covering a range of length scales, including electron channeling contrast imaging (ECCI), electron backscatter diffraction (EBSD), and high-resolution transmission microscopy (HR-TEM), to explore the microstructure characteristics of bonding and overall structure development of CoCrFeMnNi microparticles after impact in CS. HR-TEM lamellae were prepared using focused ion beam milling. Additionally, the effects of deformation field variables on microstructure development were determined through finite element modeling (FEM) of microparticle impacts. The ECCI, EBSD, and HR-TEM analyses revealed an interplay between dislocation-driven processes and twinning, leading to the development of four distinct deformation microstructures. Significant grain refinement occurs at the interface through continuous dynamic recrystallization (CDRX) due to high strain and temperature rise from adiabatic deformation, signs of softening, and ASI. Near the interface, a necklace-like structure of refined grains forms around grain boundaries, along with elongated grains, resulting from the coexistence of dynamic recovery and discontinuous dynamic recrystallization (DDRX) due to lower temperature rise and strain. Towards the particle or substrate interior, concurrent twinning and dislocation-mediated mechanisms refine the structure, forming straight, curved, and intersected twins. At the top of the particles, only deformed grains with a low dislocation density are observed. Our results showed that DRX induces microstructure softening in highly strained interface areas, facilitating atomic bonding in CoCrFeMnNi. HR-TEM investigation confirms the formation of atomic bonds between particles and substrate, with a gradual change in crystal lattice orientation from the particle to the substrate and the occurrence of some misfit dislocations and vacancies at the interface. Finally, the findings of this research suggest that softening and ASI, even in materials resistant to softening, are required to establish bonding in CS.

Key words: Multi-length scale microstructure characteristics of bonding in cold spray, DRX-induced softening and its role in bonding, Interplay between twinning-induced hardening and DRX-driven softening, EBSD & HR-TEM, CoCrFeMnNi high entropy alloys