Characterization and modeling of the bonding process in cold spray additive manufacturing

Wang, Xuemei; Feng, Feng; Klecka, Michael A.; Mordasky, Matthew; Garofano, Jacquelynn; El-Wardany, Tahany; Nardi, Aaron; Champagne, Victor K.

doi:10.1016/j.addma.2015.03.006

Cited by 81 publications

(45 citation statements)

References 23 publications

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“…In order to improve the coating quality, the bonding mechanism is always a hot topic in cold spray (Ref 18,19). Currently, mechanical (Ref [20][21][22][23][24] and metallurgical bonding ( Ref 7,10,25) is considered as the main bonding mechanisms in cold spray. At the oxide-free interface and metal-to-metal contact, metallurgical bonding is formed as a chemical reaction between deposited particles or interface between coating and substrate ( Ref 26).…”

Section: Introductionmentioning

confidence: 99%

Strengthened Peening Effect on Metallurgical Bonding Formation in Cold Spray Additive Manufacturing

et al. 2019

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Cold spraying is a solid-state coating process and promising technique for additive manufacturing. However, questions raise about the bonding mechanism between the particles forming the coating. In this study, the strengthened peening effect is proposed as the determining factor for the formation of metallurgical bonding in cold spray additive manufacturing. Ni coatings and single splats were produced on Al substrates with different propelling gas pressures. Contrary to common understanding, no metallurgical bonding was observed in single-particle impact, even at the pressure of 3.7 MPa. However, the metallurgical bonding was observed at the full coating deposition through the existence of diffusion after heat treatment. Thus, the strengthened peening effect of subsequent particles with successive impact energy might be the determining factor for the formation of metallurgical bonding. Actually, strengthened peening effect significantly improved the coating quality through enhanced metallurgical bonding, which was proved by the increasing adhesion strength and decreasing porosity.

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Section: Introductionmentioning

confidence: 99%

Strengthened Peening Effect on Metallurgical Bonding Formation in Cold Spray Additive Manufacturing

et al. 2019

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“…Of the AM technologies capable of performing repairs, the most common approaches have been DED and supersonic particle deposition (SPD). Unlike the AM processes previously discussed, the unique characteristic of SPD is that the deposited powder material retains its initial phase composition and grain structure upon its base component [118]. On the other hand, DED is often utilized more extensively as it offers the ability to repair critical components to higher degrees of accuracy [119,120].…”

Section: Maintenance and Repair Of Aircraft Componentsmentioning

confidence: 99%

Review: The Impact of Metal Additive Manufacturing on the Aerospace Industry

Yusuf

Cutler

Gao

2019

Metals

215

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Metal additive manufacturing (AM) has matured from its infancy in the research stage to the fabrication of a wide range of commercial functional applications. In particular, at present, metal AM is now popular in the aerospace industry to build and repair various components for commercial and military aircraft, as well as outer space vehicles. Firstly, this review describes the categories of AM technologies that are commonly used to fabricate metallic parts. Then, the evolution of metal AM used in the aerospace industry from just prototyping to the manufacturing of propulsion systems and structural components is also highlighted. In addition, current outstanding issues that prevent metal AM from entering mass production in the aerospace industry are discussed, including the development of standards and qualifications, sustainability, and supply chain development.

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“…The particles collide with the cold part forming a solid-state metallurgical bond. It is, therefore, best suited for the addition of near-net-shape features onto components, such as bosses, lugs onto shafts or coating application [18][19][20][21][22]. Another technology is sheet lamination, where each layer is represented by a sheet/foil.…”

Section: Processes Reviewmentioning

confidence: 99%

Metal Additive Manufacturing Cycle in Aerospace Industry: A Comprehensive Review

Barroqueiro

Andrade‐Campos

Valente

et al. 2019

JMMP

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Additive Manufacturing (AM) is the forefront of advanced manufacturing technologies and has the potential to revolutionize manufacturing, with a dramatic change in the design and project paradigms. A comprehensive review of existent metal AM processes, processable materials, respective defects and inspection methods (destructive and non-destructive) is presented in a succinct manner. Particularly, the AM design optimization methodologies are reviewed and their threats and constraints discussed. Finally, an aerospace industry case study is presented and several cost-effective examples are enumerated.

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Characterization and modeling of the bonding process in cold spray additive manufacturing

Cited by 81 publications

References 23 publications

Strengthened Peening Effect on Metallurgical Bonding Formation in Cold Spray Additive Manufacturing

Strengthened Peening Effect on Metallurgical Bonding Formation in Cold Spray Additive Manufacturing

Review: The Impact of Metal Additive Manufacturing on the Aerospace Industry

Metal Additive Manufacturing Cycle in Aerospace Industry: A Comprehensive Review

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