Bonding Mechanisms in Cold Spraying: The Contributions of Metallurgical and Mechanical Components

Hussain, Tanvir; McCartney, D.G.; Shipway, P.H.; Zhang, D.

doi:10.1007/s11666-009-9298-1

Cited by 311 publications

(131 citation statements)

References 27 publications

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“…Over two decades of fundamental studies (Ref [11][12][13][14][15][16][17][18][19] have elucidated the theoretical principles of the process, which has led to the development of commercial equipment and applications . While the CGDS process has become established in recent years, particularly for repairs , it is still in its infancy as an AM process (Ref [28][29][30][31][32][33][34][35][36] (Ref 13) proposed that the critical velocity for titanium is above 700 m/s for adiabatic sheer instability to occur.…”

Section: Introductionmentioning

confidence: 99%

Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

et al. 2016

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Titanium parts are ideally suited for aerospace applications due to their unique combination of high specific strength and excellent corrosion resistance. However, titanium as bulk material is expensive and challenging/costly to machine. Production of complex titanium parts through additive manufacturing looks promising, but there are still many barriers to overcome before reaching mainstream commercialization. The cold gas dynamic spraying process offers the potential for additive manufacturing of large titanium parts due to its reduced reactive environment, its simplicity to operate, and the high deposition rates it offers. A few challenges are to be addressed before the additive manufacturing potential of titanium by cold gas dynamic spraying can be reached. In particular, it is known that titanium is easy to deposit by cold gas dynamic spraying, but the deposits produced are usually porous when nitrogen is used as the carrier gas. In this work, a method to manufacture low-porosity titanium components at high deposition efficiencies is revealed. The components are produced by combining low-pressure cold spray using nitrogen as the carrier gas with low-cost titanium powder produced using the Armstrong process. The microstructure and mechanical properties of additive manufactured titanium components are investigated.

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Section: Introductionmentioning

confidence: 99%

Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

et al. 2016

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“…The other mechanism which has high contribution to adhesion is mechanical interlocking. The coating stereometry should then depend mostly on degree of particle deformation and hence on its impact velocity [1,2].…”

Section: Introductionmentioning

confidence: 99%

Effect of Gas Pressure and Temperature on Stereometric Properties of Al+Al2O3 Composite Coatings Deposited by LPCS Method

Winnicki¹,

Piwowarczyk²,

Małachowska³

et al. 2014

Archives of Metallurgy and Materials

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The paper deals with effect of working gas pressure and temperature on surface stereometry of coatings deposited by low-pressure cold spray method. Examinations were focused on aluminium coatings which are commonly used to protect substrate against corrosion. A commercial Al spherical feedstock powder with admixture of Al 2 O 3 (Al + 60wt.-% Al 2 O 3 ), granulation -50+10 µm, was used to coat steel, grade S235JR. The deposited coatings were studied to determine their stereometry, i.e. roughness, transverse and longitudinal waviness, topography of surface and thickness as the functions of gas pressure and temperature. A profilometer and focal microscope were used to evaluate the stereometric properties. In order to reduce the number of variables, the remaining process parameters, i.e. shape and size of de Laval nozzle, nozzle-to-substrate distance, powder mass flow rate, linear velocity of spraying gun, were kept unchanged. The investigation confirmed influence of temperature and pressure on coating thickness as well as on the surface seterometry.Keywords: Cold Spray, metal-matrix composite, roughness, waviness W artykule przedstawiono wpływ ciśnienia i temperatury gazu roboczego na sterometrię powierzchni powłok nakładanych za pomocą niskociśnieniowej metody natryskiwania na zimno. Powłoki na podłożu stalowym S235JR zostały wykonane przy użyciu komercyjnie dostępnego proszku Al z dodatkiem Al 2 O 3 (20% Al/80% Al 2 O 3 wagowo) o granulacji <50 µm, zostały wykonane powłoki na podłożu stalowym S235JR. Następnie za pomocą profilometru i mikroskopu konfokalnego określono właściwości stereometryczne powłok takie jak chropowatość, falistość, topografię powierzchni oraz grubość w funkcji temperatury i ciśnienia gazu roboczego. W celu zminimalizowania ilości zmiennych pozostałe parametry procesu nie były zmieniane. Badania potwierdziły wpływ ciśnienia i temperatury gazu na stereometrię powierzchni.

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“…There has also been a discussion about the role of mechanical contribution, i.e. interlocking [76]. This has nevertheless concerned the bonding between certain combinations of coatings and substrates, and not the general particle-particle bonding as in the build-up of CS deposits.…”

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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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Bonding Mechanisms in Cold Spraying: The Contributions of Metallurgical and Mechanical Components

Cited by 311 publications

References 27 publications

Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

Effect of Gas Pressure and Temperature on Stereometric Properties of Al+Al2O3 Composite Coatings Deposited by LPCS Method

Cold spraying – A materials perspective

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