Cold Gas Dynamic Manufacturing – A new approach to Near-Net Shape Metal Component Fabrication

Morgan, R.P.; Sutcliffe, Christopher; Pattison, J.; Murphy, Michael; Gallagher, C.; Papworth, A. J.; Fox, Peter; O’Neill, W

doi:10.1557/proc-758-ll2.6

Cited by 9 publications

(8 citation statements)

References 7 publications

(9 reference statements)

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“…As a spray forming process similar to thermal spraying, CS can also be used to directly fabricate components because of its high deposition rate and ability to combine many dissimilar materials to produce a single component without obvious melting or oxidation of the feedstock, 112 which is similar to near-net shape manufacturing technology. As such it is possible to construct components with freeform surfaces, internal channels and embedded devices.…”

Section: Near-net Forming or Additive Manufacturingmentioning

confidence: 99%

“…Apart from coating deposition applications, 110 additive manufacturing with CS (also called Cold Gas Dynamic Manufacturing (CGDM) 111,112 ) has also been proposed based on its low processing temperature, high DE and controllable spray print. By this method, components can be fabricated with relatively complex shapes from dissimilar materials, while retaining the inherent materials properties, having great potential in rapid prototyping and component restoration, which may even overturn the traditional fabrication and restoration techniques.…”

Section: Introductionmentioning

confidence: 99%

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A Review of Advanced Composite and Nanostructured Coatings by Solid-State Cold Spraying Process

Assadi

Gaertner

et al. 2018

Critical Reviews in Solid State and Materials Sciences

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Cold spraying (CS) has been widely explored over the last decade due to its low process temperature and limited thermal effect on spray materials. As a solid-state process, the inherent deficiencies of traditional thermal spraying such as oxidation, decomposition and grain growth are avoided. This article summarizes the research work on the fabrication of composites and nanostructured coatings by the promising CS process. After a brief introduction to CS and its deposition mechanisms, the preparation methods of spray powders are classified. Different methods are appropriate for particles of various properties, and the tendency is to design composite powders by combined methods in order to create coatings with specified properties. Then the co-deposition mechanism of composite particles as well as research findings on metal-metal, metal-ceramic and metal-intermetallic composite coatings are reviewed concerning the deposition characteristics, microstructure and its relation to properties. Moreover, CS has been used to deposit a variety of nanostructured materials, including metals, metal-ceramic composites, and even ceramics, retaining their nanocrystalline nature in the coating without grain growth or phase transformation. Finally, the potential applications of CS and issues to be addressed in coating deposition are discussed.

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Section: Near-net Forming or Additive Manufacturingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Review of Advanced Composite and Nanostructured Coatings by Solid-State Cold Spraying Process

Assadi

Gaertner

et al. 2018

Critical Reviews in Solid State and Materials Sciences

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“…[1][2][3][4][5][6][7][8][9][10]. The mixture ratio of kerosene to oxygen was fixed at the stoichiometric ratio for complete combustion.…”

Section: Warm Spray Conditionsmentioning

confidence: 99%

“…(1) The gas in the CC consists of 8 gas species; CO, CO 2 After obtaining gas pressure, temperature and other thermodynamic properties in the MC, the gas flow from the throat of the C-D nozzle to the barrel exit was calculated. Main assumptions used are listed below;…”

Section: Numerical Calculations Of Warm Spraymentioning

confidence: 99%

Warm Spray Forming of Ti-6Al-4V

et al. 2013

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Warm spray (WS) is a modification of high-velocity oxy-fuel spraying, in which the temperature of the supersonic gas flow generated by the combustion of kerosene and oxygen is controlled by diluting the combustion flame with an inert gas such as nitrogen. The inert gas is injected into the mixing chamber placed between the combustion chamber and the powder feed ports, thus the temperature of the propellant gas can be controlled from~700 to 2,000 K. Since WS allows for higher particle temperatures in comparison to cold spray, warm sprayed particles are more softened upon impact, thus resulting in greater deformation facilitating the formation of shear instability for bonding. Recently, the combustion pressure of WS has been increased from 1 (low-pressure warm spray) to 4 MPa (high-pressure warm spray) in order to increase the velocity of sprayed particles. Effects of spray parameters on microstructure, mechanical properties, and splats formation of Ti-6Al-4V were systematically studied. Obtained coatings were examined by analyzing the coating cross-section images, microhardness as well as oxygen content. In addition, flattening ratio of splats was calculated as a function of nitrogen flow rate. It was found that the increased particle velocity caused by the increased combustion pressure had significant beneficial effects in terms of improving density and controlling the oxygen level in the sprayed Ti-6Al-4V coatings.

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“…However, most of the material appears to be only mechanically interlocked, with the etch attacking the boundaries between the splats. Auger electron spectroscopy of a sample fractured under high vacuum revealed oxygen at the fracture interface to a depth of approximately 30 nm [3] which is similar to the thickness of the oxide layer on passivated aluminium powders. SEM analysis of the fracture surface also shows that mechanical interlocking is the predominant bonding mechanism.…”

Section: Resultsmentioning

confidence: 65%