The invention relates to an apparatus and process for solid-state deposition
and consolidation of powder particles entrained in a subsonic or sonic gas jet
onto the surface of an object. Under high velocity impact and thermal plastic deformation,
the powder particles adhesively bond to the substrate and cohesively bond together
to form consolidated materials with metallurgical bonds. The powder particles and
optionally the surface of the object are heated to a temperature that reduces yield
strength and permits plastic deformation at low flow stress levels during high
velocity impact, but which is not so high as to melt the powder particles.
