Development of Sustainable Cold Spray Coatings and 3D Additive Manufacturing Components for Repair/Manufacturing Applications: A Critical Review

Abstract

This review article presents the findings of a comprehensive state-of-the-art literature review of the scientific and technological progress of the cold spray process in the field of repair/remanufacturing using the concept of additive manufacturing. A thorough study was conducted on the potential of this technology to form (a) both thin and thick coatings; (b) the ability to fabricate 3D freeform components in a single process, while benefiting from reduced residual stress level compared to conventional thermal spray coatings processes such as high velocity oxy-fuel (HVOF) or plasma spraying. A systematic overview of the process technology, particularly focusing on the suitability of ceramic-metallic (cermet) composite particles used as feedstock in the deposition was conducted; further elaboration was made pertinent to particle impact and bonding mechanisms during the deposition.

Additive Manufacturing for Repair and Restoration in Remanufacturing: An Overview from Object Design and Systems Perspectives

“…Other 22% Furthermore, die repair was reported in two publications, whereby Kattire et al [74] first conducted an experiment to overlay the surface of a die. In contrast, Pathak and Saha [75] reported on an overlay process on the damaged part of a flap transmission tee box by using the cold spray technique. Similarly, another publication by Portolés et al [76] focused on the reconstruction of a bracket from one original equipment manufacturer part by eliminating the material of the broken area and then reconstructing it by using the undamaged remaining material as the base.…”

“…Such AM technology was addressed in 25 publications for DED, which specified the use of laser cladding [61,69,70,73] and laser metal deposition [28] as well as three other publications for powder bed fusion technology, which uses electron beam melting [29,76]. Meanwhile, one publication described the material extrusion technology using fused deposition modeling [30] and the metal-based AM of cold spray [75].…”

Metal Additive Manufacturing Cycle in Aerospace Industry: A Comprehensive Review

“…The particles collide with the cold part forming a solid-state metallurgical bond. It is, therefore, best suited for the addition of near-net-shape features onto components, such as bosses, lugs onto shafts or coating application [18][19][20][21][22]. Another technology is sheet lamination, where each layer is represented by a sheet/foil.…”

Cold-Sprayed AZ91D Coating and SiC/AZ91D Composite Coatings

“…In cold spraying, particles are accelerated to a high velocity (300~1200 m•s −1 ) by a high-pressure thermal gas through a de Laval-type nozzle. Then, the particles can deposit onto a substrate and form a coating once the particle velocity exceeds the critical velocity of the material [9,10]. In the view of bonding, the jet formation of impact couples is viewed as the necessary condition.…”