Current Implementation Status of Cold Spray Technology: A Short Review

Chu, Xin; Lan, Haiming; Huang, Renzhong; Huang, Jibo; Xie, Yingchun; Huang, Jian; Huang, Guosheng

doi:10.1007/s11666-022-01382-4

Cited by 52 publications

(16 citation statements)

References 76 publications

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“…However, when compared with Ni-based superalloys, their structural characteristics are inherently different. As such, it can be expected that their deformation and recrystallization mechanisms will also differ [ 69 ].…”

Section: Structural and Microstructural Evolutionmentioning

confidence: 99%

Solid-State Cold Spray Additive Manufacturing of Ni-Based Superalloys: Processing–Microstructure–Property Relationships

et al. 2023

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Ni-based superalloys have been extensively employed in the aerospace field because of their excellent thermal and mechanical stabilities at high temperatures. With these advantages, many sought to study the influence of fusion-reliant additive manufacturing (AM) techniques for part fabrication/reparation. However, their fabrication presents many problems related to the melting and solidification defects from the feedstock material. Such defects consist of oxidation, inclusions, hot tearing, cracking, and elemental segregation. Consequentially, these defects created a need to discover an AM technique that can mitigate these disadvantages. The cold spray (CS) process is one additive technique that can mitigate these issues. This is largely due to its cost-effectiveness, low temperature, and fast and clean deposition process. However, its effectiveness for Ni-based superalloy fabrication and its structural performance has yet to be determined. This review aimed to fill this knowledge gap in two different ways. First, the advantages of CS technology for Ni-based superalloys compared with thermal-reliant AM techniques are briefly discussed. Second, the processing–structure–property relationships of these deposits are elucidated from microstructural, mechanical, and tribological (from low to high temperatures) perspectives. Considering the porous and brittle defects of CS coatings, a comprehensive review of the post-processing techniques for CS-fabricated Ni superalloys is also introduced. Based on this knowledge, the key structure-property mechanisms of CS Ni superalloys are elucidated with suggestions on how knowledge gaps in the field can be filled in the near future.

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Section: Structural and Microstructural Evolutionmentioning

confidence: 99%

Solid-State Cold Spray Additive Manufacturing of Ni-Based Superalloys: Processing–Microstructure–Property Relationships

et al. 2023

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“…2020; Koivuluoto 2022; Sun et al. 2022), respiratory drug delivery (Dietzel 2016) and ocean spray (Veron 2015). In these processes, the fluids contain dispersed objects such as metal or coal particles, polymer or catalyst and pollutant plastics, which complicate their atomisation processes.…”

Section: Introductionmentioning

confidence: 99%

“…The atomisation of a suspension is a fundamental issue for many natural phenomena and practical applications, such as slurry-fuel atomisation (Gvozdyakov & Zenkov 2021;Noh et al 2022), spray coating (Suhag et al 2020;Koivuluoto 2022;Sun et al 2022), respiratory drug delivery (Dietzel 2016) and ocean spray (Veron 2015). In these processes, the fluids contain dispersed objects such as metal or coal particles, polymer or catalyst and pollutant plastics, which complicate their atomisation processes.…”

Section: Introductionmentioning

confidence: 99%

Breakup of particle-laden droplets in airflow

Xu,

Wang,

Che

2023

J. Fluid Mech.

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The atomisation of a suspension containing liquid and dispersed particles is prevalent in many applications. Previous studies of droplet breakup mainly focused on homogeneous fluids, and the heterogeneous effect of particles on the breakup progress is unclear. In this study, the breakup of particle-laden droplets in airflow is investigated experimentally. Combining synchronised high-speed images from the side view and the 45 $^\circ$ view, we compare the morphology of particle-laden droplets with that of homogeneous fluids in different breakup modes. The results show that the higher effective viscosity of particle-laden droplets affects the initial deformation, and the heterogeneous effect of particles appears in the later breakup stage. To evaluate the heterogeneous effect of particles quantitatively, we eliminate the effect of the higher effective viscosity of particle-laden droplets by comparing cases corresponding to the same inviscid Weber number. The quantitative comparison reveals that the heterogeneous effect of particles accelerates the fragmentation of the liquid film and promotes localised rapid piercing. A correlation length that depends on the particle diameter and the volume fraction is proposed to characterise the length scale of the concentration fluctuation under the combined effect of the initial flattening and later stretching during the droplet breakup process. Based on this correlation length, the fragment size distributions are analysed, and the scaling results agree well with the experimental data.

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“…Recently, CSAM has been gaining popularity due to its ability to build large components at rates of kilograms per hour. 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].…”

Section: Introductionmentioning

confidence: 99%

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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Current Implementation Status of Cold Spray Technology: A Short Review

Cited by 52 publications

References 76 publications

Solid-State Cold Spray Additive Manufacturing of Ni-Based Superalloys: Processing–Microstructure–Property Relationships

Solid-State Cold Spray Additive Manufacturing of Ni-Based Superalloys: Processing–Microstructure–Property Relationships

Breakup of particle-laden droplets in airflow

A Continuous Toolpath Strategy from Offset Contours for Robotic Additive Manufacturing

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