A workflow for designing contoured axisymmetric nozzles for enhancing additively manufactured cold spray deposits

Zavalan, Florentina-Luiza; Rona, Aldo

doi:10.1016/j.addma.2022.103379

Cited by 6 publications

(4 citation statements)

References 56 publications

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“…where η ext and η ga are resource efficiencies of the extrusion process and gas atomization, respectively, i.e., 95%; η CM is the resource efficiency of CM, which is a fraction of the volume of the part to the volume of the bar; η CSAM is the powder deposition efficiency, which is the ratio of mass of the part to powder (78%) [46]. The energy consumed to produce the bar and powder are denoted as E CM and E CSAM , respectively, and their respective raw material energy consumption is denoted by EE ingot .…”

Section: Feedstock Materials Productionmentioning

confidence: 99%

Life Cycle Assessment of Cold Spray Additive Manufacturing and Conventional Machining of Aluminum Alloy Flange

Kumar,

Palanisamy,

Krishnan

et al. 2023

Metals

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Cold spray additive manufacturing (CSAM) is generally used to repair worn components and build complex on-demand parts by depositing metal powder layer-wise using compressed air. Previous studies on CSAM were focused on printing parameters, materials properties, and printed part mechanical performance. However, the energy consumption and environmental impacts of CSAM processes have not yet been investigated, which are essential factors for sustainable manufacturing. This study aims to investigate the carbon footprint of the CSAM process and compare it with conventional machining processes and other additive manufacturing. The life cycle assessment methodology was followed to calculate the carbon footprint of a pipe flange, considering rod or tube as a feedstock. Results revealed that the machined flange from the tube had the lowest CO2-eq emissions of 31 kg CO2-eq due to low rough machining energy consumption and scrap production, compared to the machined flange from a rod and a printed flange from powder. Moreover, the life cycle carbon emissions increased by 8% and 19% in case of the printed and machined flanges, with uncertainties of 4% and 9%, respectively, when changing feedstock CO2 emissions. From a regional perspective, the CSAM process was responsible for the lowest CO2-eq emissions in Tasmania and South Australia.

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Section: Feedstock Materials Productionmentioning

confidence: 99%

Life Cycle Assessment of Cold Spray Additive Manufacturing and Conventional Machining of Aluminum Alloy Flange

Kumar,

Palanisamy,

Krishnan

et al. 2023

Metals

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“…Solid-state cold spray (CS) is a new technology that uses a supersonic jet of compressed gas to impact and bond the powder particles onto a substrate; meanwhile, the powder particles are heated by the jet of gas at a temperature below the melting point of the powder materials [ 1 , 2 ]. This enables the formation of coatings from solid-state particles, effectively reducing or eliminating detrimental effects such as evaporation, melting, high-temperature oxidation, undesired phase transformation, crystallization, grain growth, gas release, residual stresses, and other typical challenges encountered in conventional thermal spray technologies [ 3 , 4 ]. By eliminating the harmful impact of high temperatures on coatings and substrates, CS technology opens up remarkable opportunities and advantages, making it a highly promising technique for a wide range of industrial applications.…”

Section: Introductionmentioning

confidence: 99%

Comparison of Cold-Sprayed Coatings of Copper-Based Composite Deposited on AZ31B Magnesium Alloy and 6061 T6 Aluminum Alloy Substrates

Xue

Shao

et al. 2023

Materials

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Copper-coated graphite and copper mixture powders were deposited on AZ31B magnesium alloy and 6061 T6 aluminum alloy substrates under different process parameters by a solid-state cold spray technique. The microstructure of the copper-coated graphite and copper composite coatings was visually examined using photographs taken with an optical microscope and a scanning electron microscope. The surface roughness of the coatings was investigated with a 3D profilometer. The thickness of the coatings was determined through the analysis of the microstructure images, while the adhesion of the coatings was characterized using the scratch test method. The results indicate that the surface roughness of the coatings sprayed on the two different substrates gradually decreases as gas temperature and gas pressure increase. Additionally, the thickness and adhesion of the coatings deposited on the two different substrates both increase with an increase in gas temperature and gas pressure. Comparing the surface roughness, thickness, and adhesion of the coatings deposited on the two different substrates, the surface roughness and adhesion of the coatings on the soft substrate are greater than those of the coatings on the hard substrate, while the thickness of the coatings is not obviously affected by the hardness of the substrate. Furthermore, it is noteworthy that the surface roughness, thickness, and adhesion of the copper-coated graphite and copper composite coatings sprayed on the two different substrates exhibit a distinct linear relationship with particle velocity.

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“…Forero-Sossa 10 investigated the effect of the nozzle geometry on the deposition of hydroxy-apatite particles in LPCS and demonstrated that the nozzle geometry affects the coating uniformity. Zavalan 11 employed an objective multi-optimization method to optimize the nozzle structure and improve nozzle performance. Klinkov 12 employed a cylindrical barrel with a double-edged bevelled exit vortex to generate a high-speed two-phase flow.…”

Section: Introductionmentioning

confidence: 99%

Optimizing of particle accelerated rotor parameters using the discrete element method

Sun,

Wei,

Yang

et al. 2023

Sci Rep

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The acceleration capability of a centrifugal jet rotor plays a crucial role in achieving a high injection velocity of powder particles in the centrifugal impact moulding process. In this regard, the focus of this article is on optimization of the runner shape. To this end, the lengths of the first and second acceleration sections (L1 and L2), and the angles between the first and second acceleration sections and between the second and third sections (α1 and α2) are considered as the rotor parameters. Simulations were conducted using multiple discrete elements to explore the influence of multiple input parameters on the response value, and a regression model was established between the parameters and the particle injection rate. The experimental results show that the selected parameters significantly affect the rate of particle injection, and the interactions between the parameters L1 and L2, and between L2 and α2 have the largest effects. The results reveal that applying the optimized parameters improves the particle injection speed by 7.85% when compared to the pre-optimization model. This improvement in the rotor acceleration provides the basis for improving the efficiency of centrifugal impact moulding of metal powders.

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A workflow for designing contoured axisymmetric nozzles for enhancing additively manufactured cold spray deposits

Cited by 6 publications

References 56 publications

Life Cycle Assessment of Cold Spray Additive Manufacturing and Conventional Machining of Aluminum Alloy Flange

Life Cycle Assessment of Cold Spray Additive Manufacturing and Conventional Machining of Aluminum Alloy Flange

Comparison of Cold-Sprayed Coatings of Copper-Based Composite Deposited on AZ31B Magnesium Alloy and 6061 T6 Aluminum Alloy Substrates

Optimizing of particle accelerated rotor parameters using the discrete element method

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