‘Cold spray +’ as a new hybrid additive manufacturing technology: a literature review

Li, Wenya; Cao, Congcong; Wang, Guoqing; Wang, Feifan; Xu, Yaxin; Yang, Xiawei

doi:10.1080/13621718.2019.1603851

Cited by 70 publications

(16 citation statements)

References 150 publications

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“…A large number of materials have been successfully deposited, such as Cu and its alloys [8][9][10], Al and its alloys [11][12][13], metal-metal composites [4,[14][15][16], metal-ceramic composites [17][18][19][20], Inconel 718 [21][22][23], Ti [24] and Ti6Al4V [25][26][27]. However, over the years, it has remained very difficult to produce highstrength Ti6Al4V deposits [28,29], although in situ shot peening assisting cold spray [30] or post-treatment with heat treatment and thermostatic isostatic pressure [6,9,31,32] can improve their densities.…”

Section: Introductionmentioning

confidence: 99%

Cold Spray Additive Manufacturing of Ti6Al4V: Special Nozzle Design Using Numerical Simulation and Experimental Validation

Cao

Zhang

et al. 2022

Coatings

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Cold spray additive manufacturing (CSAM) shows great potential in titanium-alloy production as it is a solid-state process. However, data published so far have demonstrated the difficulty of producing dense and high-strength Ti alloy parts. Our previous studies have shown that nozzle design together with high-cost helium propulsive gas plays a crucial role in particle acceleration. In this work, special nozzles for Ti alloy were designed and validated experimentally with commercially available Ti6Al4V powder. Simulation results show that particle impact temperature increases remarkably for a long convergent length, while particle kinetic energy slightly increases, which is validated by experiments. The relationship between the particle impact temperature and practice diameter shows the first increase and then decrease. The experimental results show that as the nozzle convergent section becomes longer, the edges of the single-pass deposits become smoother, and the width, density, deposition efficiency, and microhardness of the single-pass deposits increase.

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Section: Introductionmentioning

confidence: 99%

Cold Spray Additive Manufacturing of Ti6Al4V: Special Nozzle Design Using Numerical Simulation and Experimental Validation

Cao

Zhang

et al. 2022

Coatings

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“…In understanding the impact behaviors of micro-particles, effectively measuring the velocity and monitoring the motion of micro-particles in the high-speed impact process are two of the primary challenges [ 21 , 22 , 23 , 24 , 25 , 26 , 27 ]. Currently, expensive imaging systems with ultra-high fps and resolution are the main solutions for monitoring the high-speed motion of micro-particles [ 28 , 29 ].…”

Section: Introductionmentioning

confidence: 99%

High-Speed Micro-Particle Motion Monitoring Based on Continuous Single-Frame Multi-Exposure Technology

Wang

Xue

et al. 2022

Materials

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The impact phenomena of solid micro-particles have gathered increasing interest across a wide range of fields, including space debris protection and cold-spray additive manufacturing of large, complicated structures. Effective motion monitoring is essential to understanding the impact behaviors of micro-particles. Consequently, a convenient and efficient micro-particle motion monitoring solution is proposed based on continuous single-frame multiple-exposure imaging technology. This method adopts a camera with excellent low-light performance coupled with high-frequency light-emitting diode (LED) flashes to generate short interval illumination. This technology can, in theory, achieve 1 million effective frames per second (fps) and monitor particles as small as 10 microns with speeds up to 12 km/s. The capabilities of the proposed method were validated by a series of micro-particle motion monitoring experiments with different particles sizes and materials under varying camera configurations. The study provides a feasible and economical solution for the velocity measurement and motion monitoring of high-speed micro-particles.

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“…Cold spray is a novel and environmentally-friendly technology, which can produce metal, ceramic, cermets, and organic coatings on the surface of different materials [ 9 , 10 ]. Unlike other thermal spraying techniques, solid-state particles at a low temperature are accelerated to a high velocity to impact the substrate and form a dense, non-oxidized, and adherent coating.…”

Section: Introductionmentioning

confidence: 99%

Influence of Heat Treatment on Microstructure, Mechanical Property, and Corrosion Behavior of Cold-Sprayed Zn Coating on Mg Alloy Substrate

Zhou

Chen

et al. 2022

Materials

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The influence of post-process heat treatment on cold-sprayed Zn coatings on the Mg alloy substrate was investigated at different temperatures (150, 250, and 350 °C) and times (2, 8, and 16 h). Phase, microstructure, microhardness, and tensile strength of Zn coatings were analyzed before and after heat treatment. Corrosion properties of Zn coatings after heat treatment were investigated in simulated body fluid by using potentiodynamic polarization and immersion testing. Results show that although the heat treatment presented little effect on phase compositions of Zn coatings, the full width at half maxima of the Zn phase decreased with the heat temperature and time. Zn coatings presented comparable microstructures before and after heat treatment in addition to the inter-diffusion layers, and the inter-diffusion layer was dependent on the heat temperature and time. Both the thickness and the microhardness of inter-diffusion layers were increased with the heat temperature and time, with the largest thickness of 704.1 ± 32.4 μm and the largest microhardness of 323.7 ± 104.1 HV0.025 at 350 °C for 2 h. The microhardness of Zn coating was significantly decreased from 70.8 ± 5.6 HV0.025 to 43.9 ± 12.5 HV0.025, with the heat temperature from the ambient temperature to 350 °C, and was slightly decreased with the heat time at 250 °C. Although the tensile strength of Zn coating was slightly increased by heat treatment, with the highest value of 40.9 ± 3.9 MPa at 150 °C for 2 h, excessive heat temperature and time were detrimental to the tensile strength, with the lowest value of 6.6 ± 1.6 MPa at 350 °C for 2 h. The heat temperature and heat time presented limited effects on the corrosion current and corrosion ratio of the Zn coatings, and Zn coatings before and after heat treatment effectively hindered the simulated body fluid from penetrating into the substrate. The corrosion behavior of Zn coatings was discussed in terms of corrosion products and microstructures after immersion.

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‘Cold spray +’ as a new hybrid additive manufacturing technology: a literature review

Cited by 70 publications

References 150 publications

Cold Spray Additive Manufacturing of Ti6Al4V: Special Nozzle Design Using Numerical Simulation and Experimental Validation

Cold Spray Additive Manufacturing of Ti6Al4V: Special Nozzle Design Using Numerical Simulation and Experimental Validation

High-Speed Micro-Particle Motion Monitoring Based on Continuous Single-Frame Multi-Exposure Technology

Influence of Heat Treatment on Microstructure, Mechanical Property, and Corrosion Behavior of Cold-Sprayed Zn Coating on Mg Alloy Substrate

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