Current Status and Challenges for Unified Understanding of Bonding Mechanism in Solid Particle Deposition Process

Abstract

Cold spray (CS) technology is a "solid-phase particle deposition process without melting"; however, it has been established as an additive manufacturing technology that can be applied beyond the framework of one field of thermal spraying. The scope of application of this technology has expanded to include ceramics and polymers. There are other solid particle deposition processes besides CS, such as aerosol deposition (AD), which differ in the material type, size, impact speed, and temperature of the target particles. We can expect that there is a common intrinsic mechanism through which solid-phase particles are joined and deposited in the solid phase. This review summarizes previous studies on the mechanism of cold-spray deposition and bonding, which can be understood as a mechanochemical phenomenon in part, and it is driven by the deformation of the particles and the resulting change in the chemical state of the particle surface, and stabilization by contact in a short time. When we understand these issues correctly, the optimal mechanical conditions (material size and collision conditions) for joining particles of various materials will be systematically understood, and it will be possible to perform different fabrication processes from thin films to additive manufacturing without melting various materials.

Prediction of the Adhesion Strength of Coating in Plasma Spray Deposition

“…Due to the quick impact of the solid particles, it was inferred that the contribution of atomic diffusion to adhesion is low. Plastic deformation occurs when the substrate material and particles undergo explosive bonding upon particle contact, undulating in a wavy pattern, and layers are created by mixing in tiny interfacial areas [2]. During this collision, however, severe plastic deformation caused by particle impact might dramatically affect the bonding process, causing shear instability.…”

Future directions in ceramic additive manufacturing: Fiber reinforcements and artificial intelligence

“…In order to assess and analyze recent review articles in this area, a Scopus search was conducted in April 2023 for the specific time frame of 2018–2023. This search resulted in 165 review articles on ceramic additive manufacturing or some subset of that topic 1,3–166 . Figure 1 shows a graphical representation of the number of review articles separated into five focus areas.…”