AbstractNowadays, with severe competitive business environment, limited material sources and high cost of manufacturing, the importance of maintenance and repair is self-evident. In this field, cold spray technology is gaining more and more attention especially in light alloy components. One of the potential applications of cold spray coating is dimensional recovery of damaged structural parts. In most cases, thick coatings are necessary to fill the damages such as cavities, worn or corroded parts. Thick coatings can be deposited in a single or multiple passes giving different thermal input and stress distribution to the substrate and coating itself. The thermal input, the amount and type of residual stress (compressive or tensile) confer appreciable or depreciable characteristics to the coating mechanical properties. In this study, single and multi-pass deposition of a 0.5mm thick Al 6082 coating on the same substrate is studied to explore the number of passes effect on mechanical characteristics. In addition, one pass deposition of 0.65 and 0.8mm thick coating is investigated to examine the thickness effect. Micro-structural observation, micro-hardness measurements and X-Ray diffraction (XRD) measurement of residual stress were performed on all groups. Adhesion test and tubular coating tensile test were also carried out to characterize the coating in different cases. Observation of fractured surface was used to investigate the failure mechanism of the cold-sprayed coating. A critical discussion on the effects of pass number and thickness on mechanical properties of coated specimens is presented.