A Review of Advances in Cold Spray Additive Manufacturing

Váz, Rodolpho Fernando; Garfias, Andrea; Albaladejo-Fuentes, Vicente; Sánchez, Javier; Cano, I.G.

doi:10.3390/coatings13020267

Cited by 23 publications

(15 citation statements)

References 362 publications

(494 reference statements)

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“…Additionally, the author highlights recent advances in CGDS technology, such as the development of novel feedstock materials, and the use of computational modelling for process optimization. The document provides information on the most recent research and development initiatives in the area, making it a useful resource for academics and engineers interested in using CGDS for the creation of novel materials for aeronautical applications [25]. The authors talk about issues including impact damage, delamination, and cracking that might arise when using laminated materials in aircraft structures.…”

Section: Primary Materials Used In Space Shuttle Constructionmentioning

confidence: 99%

Materials Used in Space Shuttle: Evolution, Challenges, and Future Prospects - An Overview

Wani,

Aggarwal,

Bishnoi

et al. 2024

Preprint

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The space shuttle, a revolutionary spacecraft that has played a significant role in human space exploration, was composed of various advanced materials that were carefully selected to meet the extreme demands of spaceflight. This review paper provides a comprehensive examination of the materials historically employed in the construction of space shuttles and explores the latest trends shaping the field. The evolution of space shuttle materials is traced from the inception of the space program to contemporary missions, highlighting key milestones, challenges, and breakthroughs. Emphasis is placed on the critical role that materials play in the overall performance, safety, and sustainability of space shuttles. The paper begins by elucidating the diverse requirements that materials must fulfill in the harsh and complex environment of space, encompassing extreme temperatures, radiation exposure, and mechanical stresses. A detailed analysis of the materials utilized in the fabrication of various shuttle components, such as thermal protection systems, structural elements, and propulsion systems, is presented. Special attention is given to the challenges posed by re-entry and the strategies employed to mitigate heat-related issues. Furthermore, the review explores recent innovations and emerging materials that are reshaping the landscape of space shuttle design. Advancements in nanotechnology, composite materials, and additive manufacturing are discussed in the context of their potential applications for enhancing shuttle performance and reducing mission costs. The paper also addresses the importance of sustainability in space exploration, exploring materials with lower environmental impact and improved recyclability. The review concludes with a forward-looking perspective on the future of materials, considering ongoing research, development, and the potential incorporation of cutting-edge technologies. Insights are provided into how the evolving landscape of materials science may influence the design and manufacturing processes of the next generation of space vehicles. This paper provides an overview of the materials used in the construction of the space shuttle, including their properties, applications, and challenges. The materials used in the space shuttle are critical in ensuring the safety, performance, and longevity of the spacecraft, and understanding their characteristics and performance in space is crucial for the advancement of aerospace engineering.

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Section: Primary Materials Used In Space Shuttle Constructionmentioning

confidence: 99%

Materials Used in Space Shuttle: Evolution, Challenges, and Future Prospects - An Overview

Wani,

Aggarwal,

Bishnoi

et al. 2024

Preprint

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“…Surface modification technology has emerged as the primary approach to address this issue [10,11]. Methods such as plasma spraying, physical/chemical vapor deposition, tungsten inert gas, cold spraying, and other surface modification techniques have been extensively employed to enhance the wear resistance of titanium alloy surfaces [12][13][14][15][16]. The TC4/NiCrAlY anti-wear composite coating without cracking defects was manufactured by using an insulation layer with the in situ generation of enhanced phase transition layer technology.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Wear Resistance of Grx-Ti-BN Composite Coating on TC4 by Argon Arc Cladding

Li,

Meng,

Ding

et al. 2024

Metals

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The TC4 (Ti-6Al-4V) alloy has problems such as low material hardness, poor wear resistance, and abnormal sensitivity to adhesive wear and fretting wear. In this study, we used graphene-reinforced Ti/BN composite coatings prepared on the surface of the TC4 alloy by argon arc cladding technology. We explored the optimal content of graphene to improve its hardness and wear resistance. The physical phases and microstructures of the coatings were analyzed using an X-ray diffractometer, metallurgical microscope, and scanning electron microscope. Microhardness and wear properties of the cladding coating were measured by a Vickers hardness tester and a universal friction and wear tester. The incorporation of graphene resulted in a transformation of the reinforcing phase in the coating from TiN to Ti(N, C). The C element in the molten pool was substituted with the N element in an unending solid solution, resulting in the formation of Ti(N, C) through intermittent nucleation. As the amount of graphene in the molten pool increases, the concentration of carbon (C) also increases. This leads to the continuous growth of Ti(N, C) particles, resulting in a coarser coating structure and a decrease in coating performance. When the graphene content is 5 wt.%, the microstructure refinement of the coating is the most obvious, the microhardness is 900 HV0.2, which is 3 times higher than that of the matrix, and the wear rate is 4.9 × 10−5 mm3/(N·m), which is 4.9 times higher than that of the matrix. The wear mechanism of the coating is primarily abrasive wear with some slight adhesive wear.

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“…In recent years, the potential of CS as an additive manufacturing process has been studied [ 3 , 5 , 6 , 7 , 8 , 9 ]. Cold Spray Additive Manufacturing (CSAM) is an emerging technology that offers some advantages compared to other AM methods, including high deposition rates, deposition of temperature-sensitive materials, and minimization of tensile residual stresses [ 10 ].…”

Section: Introductionmentioning

confidence: 99%

Geometry and Microstructure Control of Remanufactured Metallic Parts by Cold Spray Additive Manufacturing

et al. 2023

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Cold Spray Additive Manufacturing (CSAM) is a thermal spray technique that is typically used for the repair of metallic components. One of the challenges of CSAM is to improve the geometrical accuracy of the sprayed parts, along with overcoming the inferiority of the mechanical properties of the deposits by tailoring their microstructure with different deposition strategies. For this, Cu, Al, Ti, and Ti6Al4V substrates were reconstructed by two Cold Spray (CS) methods: Traditional (T) and a novel strategy, Metal Knitting (MK). The final geometry, microstructure, and mechanical properties of the reconstructed parts by these two methods were compared. Additionally, we investigated the effects of annealing on the microstructure of sprayed components and its influence on adhesion, resistance to erosion, and abrasive wear. The results indicate that annealing effectively reduces the microstructure defects of the remanufactured parts (up to 30% porosity reduction) and improves the adhesive strength (i.e., below 30 MPa for as-sprayed deposits, and up to 160 MPa for heat-treated Ti4Al4V deposits). Notably, the abrasive and erosive resistance of the Cu and Al annealed deposits sprayed by MK gave very similar results compared to their bulk counterparts, suggesting that it is an efficient method for the reconstruction of damaged parts.

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A Review of Advances in Cold Spray Additive Manufacturing

Cited by 23 publications

References 362 publications

Materials Used in Space Shuttle: Evolution, Challenges, and Future Prospects - An Overview

Materials Used in Space Shuttle: Evolution, Challenges, and Future Prospects - An Overview

Microstructure and Wear Resistance of Grx-Ti-BN Composite Coating on TC4 by Argon Arc Cladding

Geometry and Microstructure Control of Remanufactured Metallic Parts by Cold Spray Additive Manufacturing

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