Abstract The effect of chemical interaction compared to mechanical influences on the bonding mechanism in cold-gas spraying is a matter of great interest. In this study, combinations of different metals (Al, Cu, steel) sprayed onto galvanized surfaces (Cr, Ni) will be used for a first approach to gain information about substrate-particle combinations with very different chemical affinities and hardnesses. Single impact morphologies and coating cross-sections are compared with respect to mechanical deformation and bonding features. The results show that a strong mechanical interaction is required to build up the contact area between spray particle and substrate. Only if the intimate contact between the materials is given, chemical interaction can contribute to bonding.