The cold spray materials deposition process

Champagne, Victor K.

doi:10.1533/9781845693787

Cited by 212 publications

(312 citation statements)

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“…1. Scholarly publications on CS include several books and review articles, covering various aspects of the process and its applications [15][16][17][18][19][20][21][22][23]. The topic is broad and spans over various fields of research, from fluid dynamics to solid mechanics.…”

Section: Introductionmentioning

confidence: 99%

Cold spraying – A materials perspective

et al. 2016

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Cold spraying is a solid-state powder deposition process with several unique characteristics, allowing production of coatings or bulk components from a wide range of materials. The process has attracted much attention from academia and industry over the past two decades.The technical interest in cold spraying is twofold: first as a coating process for applications in surface technology, and second as a solid-state additive manufacturing process, offering an alternative to selective laser melting or electron beam melting methods. Moreover, cold spraying can be used to study materials behaviour under extremely high strain rates, high pressures and high cooling rates. The cold spraying process is thus considered to be relevant for various industrial applications, as well as for fundamental studies in materials science.This article aims to provide an overview of the cold spray process, the current understanding of the deposition mechanisms, and the related models and experiments, from a materials science perspective. IntroductionCold spraying (CS) is a solid-state material deposition technique, where micron-sized particles of a powder bond to a substrate as a result of high-velocity impact and the associated severe plastic deformation. Acceleration of particles to high velocities is obtained via expansion of a pressurised and (ironically) 'hot' gas through a diverging-converging nozzle.Despite heating the process gas -which is to provide higher acceleration of the gas and also to facilitate particle deformation through thermal softening -the feedstock remains in the solid state throughout the entire process; hence the name 'cold' spraying. This is to underline the contrast to conventional thermal spraying where particles are completely or partially molten upon impact onto the substrate. Alternative terminology includes cold gas spray, micro cold spray, cold gas dynamic spray, kinetic spray, supersonic particle deposition and metal powder application (MPA), all of which refer to the same principle of solid-state powder deposition as described above. CS is used for coating and repair. It is also used for additive manufacturing (AM) at relatively high deposition rates as compared to the methods based on selective laser or electron beam melting. The main advantage of CS is that it alleviates the problems associated with high temperature processing of materials, such as oxidation and unfavourable structural changes. It is possibly the only continuous method to produce bulk components of metastable materials that are available only in the powder form, e.g. as obtained from mechanical attrition or gas atomisation. The aim of the present paper is to provide an overview of CS from a materials perspective, particularly for a broader audience in materials research, e.g. with interest in dynamic phenomena, plasticity and phase transformations. In terms of application and properties, CS is perhaps best to be compared to thermal spraying processes, as in [24,25]. In view of relevant physical phenomena, however, CS is mos...

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Section: Introductionmentioning

confidence: 99%

Cold spraying – A materials perspective

et al. 2016

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“…By means of cold spray, oxidation, structural, and compositional changes, and usual problems associated with thermal spraying-high-temperature processing of materials in general-are alleviated. These unique characteristics have attracted much attention from both academia and industry especially within the past 10 years, as indicated by numerous patents and publications including a few textbooks (Ref [1][2][3][4]. The growing interest in cold spray has been associated with a continual search for optimal spraying conditions, regarding both final properties of the deposit and economical efficiency.…”

Section: Introductionmentioning

confidence: 99%

“…It is well known that material deposition in cold spray results from high-velocity impact and subsequent deformation of particles (Ref [2][3][4][5][6][7][8][9]. The resulting adiabatic shear instabilities provide sufficient material flow and heat for bonding at the interface between particle and substrate.…”

Section: Introductionmentioning

confidence: 99%

On Parameter Selection in Cold Spraying

et al. 2011

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For cold spraying, a method for the construction of the window of deposition and the selection of optimum process parameters is presented. Initially, particle impact velocity and the critical particle velocity for bonding are worked out and expressed explicitly in terms of key process and material parameters. Subsequently, the influence of particle velocity on coating characteristics is examined in view of the results of experiments and simulations. It has been found that main coating characteristics can be described as a unique function of the ratio of particle velocity to critical velocity, here referred to as g. Finally, coating properties are linked directly to primary process parameters via parameter selection maps, where contours of constant g are plotted on a plane of gas temperature versus gas pressure. Inferences of the presented method and the resulting parameter selection maps are discussed for the example of copper as feedstock material.

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“…Metallic coatings have been successfully obtained, with subsequent development of great numbers of research papers and commercial applications. This has been feasible because the plastic deformation of metallic particles on impact and the locally released heat lead to shear instabilities of the ductile component (Ref 41,42). If preservation of the raw microstructure and composition plays a key role in the performance of anatase nanostructured photocatalysts, using such nondegrading TS techniques would be ideal.…”

Section: Cold Gas Spraymentioning

confidence: 99%

Milestones in Functional Titanium Dioxide Thermal Spray Coatings: A Review

Gardon

Guilemany

2014

J Therm Spray Tech

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Titanium dioxide has been the most investigated metal oxide due to its outstanding performance in a wide range of applications, chemical stability and low cost. Coating processes that can produce surfaces based on this material have been deeply studied. Nevertheless, the necessity of coating large areas by means of rapid manufacturing processes renders laboratory-scale techniques unsuitable, leading to a noteworthy interest from the thermal spray (TS) community in the development of significant intellectual property and a large number of scientific publications. This review unravels the relationship between titanium dioxide and TS technologies with the aim of providing detailed information related to the most significant achievements, lack of knowhow, and performance of TS TiO 2 functional coatings in photocatalytic, biomedical, and other applications. The influence of thermally activated techniques such as atmospheric plasma spray and high-velocity oxygen fuel spray on TiO 2 feedstock based on powders and suspensions is revised; the influence of spraying parameters on the microstructural and compositional changes and the final active behavior of the coating have been analyzed. Recent findings on titanium dioxide coatings deposited by cold gas spray and the capacity of this technology to prevent loss of the nanostructured anatase metastable phase are also reviewed.

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The cold spray materials deposition process

Cited by 212 publications

References 0 publications

Cold spraying – A materials perspective

Cold spraying – A materials perspective

On Parameter Selection in Cold Spraying

Milestones in Functional Titanium Dioxide Thermal Spray Coatings: A Review

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