This five-year, $648,748 National Science Foundation Project Grant supports research at Cornell University to develop a unified framework for understanding and predicting critical velocity, microstructural development, micro-scale bond strength, and macro-scale mechanical properties of cold-sprayed metal deposits. The Principal Investigator will conduct laser-induced micro-scale projectile impact testing with high-resolution imaging to produce well-defined high-velocity individual bonded particles. Microstructure and properties will be characterized using advanced electron microscopy and micro-mechanical measurements. Finite element modeling incorporating dislocation-based constitutive modeling, oxide layer fracture, and cohesive bonding will be established to predict impact-induced microstructure changes and bond strength. Micro-scale simulations will inform a macro-scale model to calculate mechanical properties of cold-sprayed specimens. This research aims to establish reliable, performance-oriented process design for cold spray additive manufacturing under the National Science Foundation's Engineering Directorate, which seeks to foster innovation and excellence in engineering research.