Classifying Powder Flowability for Cold Spray Additive Manufacturing Using Machine Learning

Valente, Richard; Ostapenko, Alissa; Sousa, Bryer C.; Grubbs, Jack; Massar, Christopher; Cote, Danielle L.; Neamtu, Rodica

doi:10.1109/bigdata50022.2020.9377948

Cited by 17 publications

(3 citation statements)

References 31 publications

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“…This powder characteristic impacted the CS powder feeding, which was 0.43 and 0.55 g•s −1 for the irregular and spherical shapes, respectively. By machine learning, Valente et al [152] show how to predict a novel powder flowability on a per-particle basis, which can help scholars develop their alloys and powders for CSAM.…”

Section: Methodsmentioning

confidence: 99%

A Review of Advances in Cold Spray Additive Manufacturing

et al. 2023

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Cold Spray Additive Manufacturing (CSAM) produces freeform parts by accelerating powder particles at supersonic speed which, impacting against a substrate material, trigger a process to consolidate the CSAM part by bonding mechanisms. The literature has presented scholars’ efforts to improve CSAM materials’ quality, properties, and possibilities of use. This work is a review of the CSAM advances in the last decade, considering new materials, process parameters optimization, post-treatments, and hybrid processing. The literature considered includes articles, books, standards, and patents, which were selected by their relevance to the CSAM theme. In addition, this work contributes to compiling important information from the literature and presents how CSAM has advanced quickly in diverse sectors and applications. Another approach presented is the academic contributions by a bibliometric review, showing the most relevant contributors, authors, institutions, and countries during the last decade for CSAM research. Finally, this work presents a trend for the future of CSAM, its challenges, and barriers to be overcome.

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Section: Methodsmentioning

confidence: 99%

A Review of Advances in Cold Spray Additive Manufacturing

et al. 2023

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“…Predicting part properties: ML can be used to prevent defects like cracking, porosity, and lack of fusion, which can lead to improving part quality and predict properties of the final product [374][375][376][377][378][379][380][381][382][383][384][385][386][387]. Feasibility analysis: Before allocating resources for 3D printing, a feasibility analysis can be carried out to ensure printability [388][389][390].…”

Section: Summary and Future Prospects For Recycling Of Chips Made Of ...mentioning

confidence: 99%

Recent Advancements in Material Waste Recycling: Conventional, Direct Conversion, and Additive Manufacturing Techniques

Golvaskar,

Ojo,

Kannan

2024

Recycling

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To improve the microstructure and mechanical properties of fundamental materials including aluminum, stainless steel, superalloys, and titanium alloys, traditional manufacturing techniques have for years been utilized in critical sectors including the aerospace and nuclear industries. However, additive manufacturing has become an efficient and effective means for fabricating these materials with superior mechanical attributes, making it easier to develop complex parts with relative ease compared to conventional processes. The waste generated in additive manufacturing processes are usually in the form of powders, while that of conventional processes come in the form of chips. The current study focuses on the features and uses of various typical recycling methods for traditional and additive manufacturing that are presently utilized to recycle material waste from both processes. Additionally, the main factors impacting the microstructural features and density of the chip-unified components are discussed. Moreover, it recommends a novel approach for recycling chips, while improving the process of development, bonding quality of the chips, microstructure, overall mechanical properties, and fostering sustainable and environmentally friendly engineering.

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“…These variables matter in laser-engineered net shaping because a specific size range of powder, 36-150 µm in diameter, must be continuously injected onto the powder bed in a controlled fashion as the laser passes over it [2]. In contrast, the size distribution and morphology matter to a lesser degree (although they remain significant and non-negligible, as discussed by Valente et al in [3] and pointed out by Hussain et al in [4]) for the cold spray additive manufacturing (CSAM) process. Nevertheless, in CSAM processing, small particles may not bond to the respective target substrate under a given set of processing conditions for one or both of the following reasons: (i) fine particles can suffer from an inability to sufficiently plastically deform (due to increased yield strengths being associated with smaller atomized particles, as they experience higher solidification rates) and therefore bond with the substrate; and (ii) from the bow shock effect [5,6].…”

Section: Introductionmentioning

confidence: 99%

Thermal Preprocessing of Rapidly Solidified Al 6061 Feedstock for Tunable Cold Spray Additive Manufacturing

Haddad

Sousa

Tsaknopoulos

et al. 2022

Metals

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In this work, the influence of thermal pre-processing upon the microstructure and hardness of Al 6061 feedstock powder is considered through the lens of cold spray processing and additive manufacturing. Since solid-state cold spray processes refine and retain microstructural constituents following impact-driven and high-strain rate severe plastic deformation and bonding, thermal pre-processing enables application-driven tuning of the resultant consolidation achieved via microstructural and, therefore, mechanical manipulation of the feedstock prior to use. Microstructural analysis was achieved via X-ray diffraction, scanning electron microscopy, transmission electron microscopy, electron backscatter diffraction, energy dispersive spectroscopy, and differential thermal calorimetry. On the other hand, nanoindentation testing and analysis were relied upon to quantify pre-processing effects and microstructural evolution influences on the resultant hardness as a function of time at 540 °C. In the case of the as-atomized powder, β-Mg2Si-, Al-Fe-, and Mg-Si-type phases were observed along polycrystalline grain boundaries. Furthermore, after a 60 min hold time at 540 °C, Al-Fe-Si-Cr-Mn- and Mg-Si-type intermetallic phases were also observed along grain boundaries. Furthermore, the as-atomized hardness at 250 nm of indentation depth was 1.26 GPa and continuously decreased as a function of hold time until reaching 0.88 GPa after 240 min at 540 °C. Finally, contextualization of the observations with tuning cold spray additive manufacturing part performance via powder pre-processing is presented for through-process and application-minded design.

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Classifying Powder Flowability for Cold Spray Additive Manufacturing Using Machine Learning

Cited by 17 publications

References 31 publications

A Review of Advances in Cold Spray Additive Manufacturing

A Review of Advances in Cold Spray Additive Manufacturing

Recent Advancements in Material Waste Recycling: Conventional, Direct Conversion, and Additive Manufacturing Techniques

Thermal Preprocessing of Rapidly Solidified Al 6061 Feedstock for Tunable Cold Spray Additive Manufacturing

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