The Study of Assessment Parameters and Performance Measurement of Cold Spray Technique: A Futuristic Approach Towards Additive Manufacturing

Abstract

In recent years, high-performance additive manufacturing (AM) is being extensively investigated by the virtue of its unique benefits over traditional manufacturing processes. Complex components of Ti, Fe, Ni alloys can be manufactured with ease; however, other nonferrous alloys such as Al alloys, Mg alloys, and Cu alloys have the melting tendency during processing by laser, electron beam, or arc, hence not appropriate to be manufactured using additive manufacturing. The most useful and powerful tool recognized in AM in the last decade is the cold spray process. This paper puts forth a review of recent research innovations and the concept to build new materials in the field of AM technology. The author has highlighted the important properties including retention of original feedstock particles and oxide-free surface deposits during the entire coating process. The present research work focuses on the basic principle, bonding mechanism and impact phenomenon, and effect of nozzle parameters on mechanical properties of deposits associated with cold spray additive manufacturing. Furthermore, the concept to develop well-bonded coated deposits and its metallurgical behavior have also been studied. Various aspects of repair and maintenance against corrosion and wear along with strength and geometry restoration have also been highlighted in this paper.

A Review of Advances in Cold Spray Additive Manufacturing

“…For the CSAM, the working or main gas commonly used is N 2 or He, or N 2 /He mixtures, but for LPCS and MPCS, compressed air is a low-cost option also [2,90,125,126]. N 2 has a lower cost than He and, due to the high consumption of the working gas, it is the choice for the main gas.…”

“…N 2 has a lower cost than He and, due to the high consumption of the working gas, it is the choice for the main gas. For CS using He instead of N 2 , the particles are propelled with a higher velocity due to He's higher atomic mass [126][127][128][129][130], e.g., CS-ed 316L (particle size 28 µm) with He reaches 750 m•s −1 , but less than 500 m•s −1 with N 2 as the working gas [131]. The CS working gas temperature is set up to high values in the CS gun heating chamber, e.g., 1100 • C for spraying 316L [132]; however, after passing through the nozzle, the gas expands, reducing the density and temperature [131,133].…”

“…The first post-treatment needed for CSAM-ed parts is the machine processes because CSAM cannot produce parts with the final geometry or roughness, which is a challenge for CSAM, as stated by Kumar and Pandey [126]. However, with the development of more complex robot manipulations, the machining has been planned for specific and essential areas of the component, such as bearing houses, screws, or axles journals, among others.…”