Pyramidal Fin Arrays Performance Using Streamwise Anisotropic Materials by Cold Spray Additive Manufacturing

Abstract

This work evaluates the thermal and hydrodynamic performance of pyramidal fin arrays produced using cold spray as an additive manufacturing process. Near-net-shaped pyramidal fin arrays of pure aluminum, pure nickel, and stainless steel 304 were manufactured. Fin array characterization such as fin porosity level and surface roughness evaluation was performed. The thermal conductivities of the three different coating materials were measured by laser flash analysis. The results obtained show a lower thermal efficiency for stainless steel 304, whereas the performances of the aluminum and nickel fin arrays are similar. This result is explained by looking closely at the fin and substrate roughness induced by the cold gas dynamic additive manufacturing process. The multi-material fin array sample has a better thermal efficiency than stainless steel 304. The work demonstrates the potential of the process to produce streamwise anisotropic fin arrays as well as the benefits of such arrays.

Data-Efficient Neural Network for Track Profile Modelling in Cold Spray Additive Manufacturing

“…The protective atmosphere-free environment allows for the fabrication of large components that are not possible with other additive manufacturing technologies, e.g., powder bed fusion, while providing a flexible selection of oxygen-sensitive powder materials [8,10,11]. These benefits have resulted in several successful demonstrations of the technology at different levels of fabrication complexity, ranging from a simple tubular structure [12], pyramidal fin array [13], to more complex parts such as topologically optimised components [14].…”

Neural Network Modelling of Track Profile in Cold Spray Additive Manufacturing

“…Such robotic CSAM effectively utilizes its high deposition rate to produce components at industrially relevant part turnaround times [7,9]. Owing to the benefits of CSAM, successful demonstrations have been reported largely in aerospace industries at different levels of fabrication complexity: Simple rotational structures [15,16] and more complex components (e.g., fin arrays) [17,18,19].…”

Melting Can Hinder Impact-Induced Adhesion

“…The notion of impact-induced adhesion, thereafter, has been implemented in powder processing through kinetic deposition or cold spray [9,10]. Kinetic deposition has proven successful in making coatings [11][12][13], in reclaiming damaged metallic surfaces [14], and in additively manufacturing bulk metallic materials [15].In this area of impact science, researchers have repeatedly observed a material-dependent critical velocity [16,17] [20] have been put forth to explain the underlying mechanism(s) of impact-induced adhesion, each of which enjoys partial support from observational data. For instance, sharp jumps observed in the temperature and strain in Lagrangian impact simulations have been used to support an argument for adiabatic shear localization [16,21].…”

“…The notion of impact-induced adhesion, thereafter, has been implemented in powder processing through kinetic deposition or cold spray [9,10]. Kinetic deposition has proven successful in making coatings [11][12][13], in reclaiming damaged metallic surfaces [14], and in additively manufacturing bulk metallic materials [15].…”