Experimental and Numerical Investigations of Titanium Deposition for Cold Spray Additive Manufacturing as a Function of Standoff Distance

Abstract

In this research, the cold spray process as an additive manufacturing method was applied to deposit thick titanium coatings onto 7075 aluminium alloy. An analysis of changes in the microstructure and mechanical properties of the coatings depending on the standoff distance was carried out to obtain the maximum deposition efficiency. The process parameters were selected in such a way as to ensure the spraying of irregular titanium powder at the highest velocity and temperature and changing the standoff distance from 20 to 100 mm. Experimental studies demonstrated that the standoff distance had a significant effect on the microstructure of the coatings and their adhesion. Moreover, its rise significantly increased the deposition efficiency. The standoff distance also significantly affected the coating microstructure and their adhesion to the substrate, but did not cause any changes in their phase composition. The standoff distance also influenced the coating porosity, which first decreased to a minimum level of 0.2% and then increased significantly to 9.8%. At the same time, the hardness of the coatings increased by 30%. Numerical simulations confirmed the results of the tests.

Simple, Scalable Route to Produce Transparent Superhydrophobic/Hydrophilic Film Surfaces

“…At a higher distance, the deformation of a particle is determined by its strength and density, which will influence the particle's kinetic energy at the same velocity [36]. Therefore, it is difficult to form a dense coating due to its low density [37,38]. However, for our coatings, the results showed that only the f-SiO 2 content influences the surface reactivity.…”

Effect of Standoff Distance on Corrosion Resistance of Cold Sprayed Titanium Coatings

“…This powder was manufactured using the hydrite-dehydrite process and supplied by Kamb Import-Export (Warsaw, Poland). On the basis of the analysis of the powder's particle size distribution, it was found that was characterized by the d10 = 18.0 µm, d50 = 35.0 µm, and d90 = 60.0 µm [25], Figure 1.…”

“…Nitrogen was applied as the process gas to the deposit titanium coatings. The maximum parameters used were a temperature of 800 • C and a pressure of nitrogen of 40 bar [25]. The cold spray equipment is shown in Figure 2.…”

Experimental and Numerical Study of Al2219 Powders Deposition on Al2219-T6 Substrate by Cold Spray: Effects of Spray Angle, Traverse Speed, and Standoff Distance

“…Although the optimum SoDs typically range from 2 to 6 cm, they vary among different materials and different systems. SoDs as large as 7 cm and 8 cm have been reported for CP Ti powders (on Al7075 substrate) [25] and IN625 powders (on IN625 substrate) [26], respectively.…”