Cold spray process (CSP) is a thermal spray technology in which coating (10–40 µm) is formed in the solid state by the impingement of power particles with supersonic velocity (200–1,200 m/s2) on coupon employing compressed gas jet, below the melting point of coating powder. It is commonly referred as cold gas dynamic spray, high velocity powder deposition, kinetic spray and kinetic energy metallisation process. Using CSP, various engineering materials (metals, polymers and ceramics) and its composites can be deposited. It is unique and promising approach for obtaining surface coating and offers various technological benefits over thermal spray as kinetic energy is employed for deposition rather than thermal energy. This offers great benefits in additive manufacturing (AM) to develop a component denser, low oxide coating free of tensile residual stresses, and undesired chemical reactions compared to conventional AM and coating techniques. Cold spray additive manufacturing (CSAM) is the powerful and emerging technique in the field of AM to develop engineering components with improved performance covering broad range of functionalities of surface, subsurface and interfaces. There are few flaws in this technique; however, extensive research work is going in CSAM and repairing of components to meet the real-time applications. The main objective of this review article is to summarise the history, effect of process parameters on surface coating, research and development in CSP along with its implementation in AM, component repairing and biomedical, antimicrobial and electrical applications. A discussion on future trends in CSAM is also provided at the end part of this article.
In this work, wire cut electrical discharge machining (WEDM) is used for the material removing processes; it is utilized for machining conductive parts where it is required to produce complicated shapes, new profiles, new geometry, new product development, and high-accuracy components. This machining process is best suitable for high-end applications such as aerospace, automations, automobile, and medical devices. At present, most of the industrial sectors choose the WEDM process because it is used to develop products in a very short development cycle and at a better economic rate. In this paper, the selected complex geometry of the metal sample was eroded away from the wire during the WEDM process, which eliminates mechanical tensions during machining. The effect of different WEDM operation variables set as wire speed, wire tension, discharge current, dielectric flow rate, and pulse on and off time on the parameter, stainless steel 304 material removing rate (MRR) using RSM, has been studied. The MRR will be maximized if the optimum sets of operational variations are used and also achieve a superior surface finish.
In this investigation, the development of an empirical relationship to determine the porosity and microhardness of the coatings through low-pressure cold-sprayed (LPCS) aluminum alloy/alumina metal matrix composite (MMC) deposit. Spray parameters like temperature, standoff distance (SOD), and powder feed rate play an essential part in the determination of the coating effectiveness. In this study, 3 variables, 5 levels of central composite rotatable design (CCD) were used to decrease the total count of the experimentation. A mathematical model has been developed to evaluate the porosity and hardness of the coated samples along with LPCS spray parameters, and the model’s applicability was inspected by ANOVA. Utilizing response surface methodology, spray parameter optimization was carried out. The deposit developed by optimal spray parameters produces the lowest surface porosity of 3.31 vol.% and a higher hardness of 137.21 HV compared with other coated samples. It is validated through the response graph. As a result, the optimized parameters for aluminum alloy/alumina metal matrix composite (MMC) coatings via LPCS are 500 degrees Celsius, 10 mm SOD, and 20 grams/min powder feed rate.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.