Toolpath planning for cold spray additively manufactured titanium walls and corners: Effect on geometry and porosity

Vargas-Uscategui, Alejandro; King, Peter C.; Yang, Sam; Chu, Clement; Li, Jianli

doi:10.1016/j.jmatprotec.2021.117272

Cited by 33 publications

(14 citation statements)

References 32 publications

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“…This has influences on the material’s properties, as summarized in Table 4 . For the CSAM samples made by the traditional strategy, the microstructures, hardness, and porosity obtained were close to those presented in the literature for 316L [ 10 , 13 , 14 , 51 ], Al [ 21 , 23 , 24 ], Cu [ 16 , 17 , 21 , 52 , 53 ], and Ti alloys [ 19 , 20 , 21 ]; however, for Metal Knitting the literature did not present any result, because it is a brand-new strategy.…”

Section: Resultssupporting

confidence: 80%

“…The literature presents the application of CS for AM for a large number of materials, highlighting the components made from 316L stainless steel [ 10 , 11 , 12 , 13 , 14 ], Cu alloys [ 15 , 16 , 17 ], and Ti alloys [ 18 , 19 , 20 , 21 ], but not limited to them since Al alloys [ 21 , 22 , 23 , 24 ], Ni superalloys [ 25 , 26 ], maraging steel [ 27 , 28 , 29 ], and many others have also been studied. Moreover, these CSAM components have interested different sectors, such as aerospace, automotive, energy, medical, and marine sectors, among others [ 8 , 30 ].…”

Section: Introductionmentioning

confidence: 99%

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Metal Knitting: A New Strategy for Cold Gas Spray Additive Manufacturing

et al. 2022

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Cold Spray Additive Manufacturing (CSAM) is an emergent technique to produce parts by the additive method, and, like other technologies, it has pros and cons. Some advantages are using oxygen-sensitive materials to make parts, such as Ti alloys, with fast production due to the high deposition rate, and lower harmful residual stress levels. However, the limitation in the range of the parts’ geometries is a huge CSAM con. This work presents a new conceptual strategy for CSAM spraying. The controlled manipulation of the robot arm combined with the proper spraying parameters aims to optimize the deposition efficiency and the adhesion of particles on the part sidewalls, resulting in geometries from thin straight walls, less than 5 mm thick, up to large bulks. This new strategy, Metal Knitting, is presented regarding its fundamentals and by comparing the parts’ geometries produced by Metal Knitting with the traditional strategy. The Metal Knitting described here made parts with vertical sidewalls, in contrast to the 40 degrees of inclination obtained by the traditional strategy. Their mechanical properties, microstructures, hardness, and porosity are also compared for Cu, Ti, Ti6Al4V, 316L stainless steel, and Al.

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Section: Resultssupporting

confidence: 80%

Section: Introductionmentioning

confidence: 99%

Metal Knitting: A New Strategy for Cold Gas Spray Additive Manufacturing

et al. 2022

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“…The nozzle was tilted by 30° for the outer and hole contours. Tilting the nozzle helps build the straight wall and sharp features on the edges [3]. Figure 6d shows the printed part on an aluminium plate.…”

Section: Resultsmentioning

confidence: 99%

“…6-DoF robots are also more exible than 3-axis cartesian or gantry mechanisms. The choice of toolpaths plays an important role in determining the geometrical accuracy and mechanical properties of the printed parts [3] [4]. In the past few decades, many methods to generate toolpaths for 3-dimentional (3D) printers have been developed…”

Section: Introductionmentioning

confidence: 99%

“…The process does not produce solidi cation defects, and generally has low thermal stresses and oxide content [11]. Frequent interruptions to the feed are problematic because the powder is conveyed through a tube or hose under high pressure from the feeder to the spray gun, where gas at a high ow rate and temperature is forced through a supersonic nozzle [3]. Stopping the powder feeder entails some lag at the gun and may result in jet instabilities.…”

Section: Introductionmentioning

confidence: 99%

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A Continuous Toolpath Strategy from Offset Contours for Robotic Additive Manufacturing

Nguyen

King²,

Vargas-Uscategui³

et al. 2022

Preprint

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Toolpath planning is an essential component of robotic additive manufacturing. An efficient toolpath strategy allows parts to be made that are geometrically accurate, free of defects, have good mechanical properties and low residual stress. Toolpaths for cold spray additive manufacturing have some technical constraints that need to be considered compared to their counterpart designed for conventional 3D printing machines. This study presents an automated toolpath planning method based on offset contours. The generated toolpath is globally continuous, layer-wise setting, making it suitable for robotic cold spray additive manufacturing. The toolpath algorithm was tested on a variety of geometries to demonstrate its robustness. One model was selected for printing using a commercial high pressure cold spray system. The experimental results show that our method is applicable to cold spray robotic additive manufacturing. The method is particularly good for web-rib structures.

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Cold Spray in Practical and Potential Applications

Wei,

He,

et al. 2024

Solid‐State Metal Additive Manufacturing

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Toolpath planning for cold spray additively manufactured titanium walls and corners: Effect on geometry and porosity

Cited by 33 publications

References 32 publications

Metal Knitting: A New Strategy for Cold Gas Spray Additive Manufacturing

Metal Knitting: A New Strategy for Cold Gas Spray Additive Manufacturing

A Continuous Toolpath Strategy from Offset Contours for Robotic Additive Manufacturing

Cold Spray in Practical and Potential Applications

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