Advances in Cold Spray

A Coating Deposition and Additive Manufacturing Process

2nd Edition - June 23, 2023
Editors: Victor K. Champagne, Dennis Helfritch, Mostafa Hassani
Language: English
Paperback ISBN:
9 7 8 - 0 - 0 8 - 1 0 3 0 1 5 - 8
eBook ISBN:
9 7 8 - 0 - 0 8 - 1 0 3 0 1 6 - 5

Advances in Cold Spray: A Coating Deposition and Additive Manufacturing Process, Second Edition reviews the fundamental processes and recent advances made in the field of cold spra… Read more

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Advances in Cold Spray: A Coating Deposition and Additive Manufacturing Process, Second Edition reviews the fundamental processes and recent advances made in the field of cold spray. This fully updated edition now includes a special chapter on Cold Spray Additive Manufacturing, along with advancements in impact modeling and simulation that allow a better understanding of the cold spray bonding mechanisms, powder synthesis and predictive modeling to improve the engineering of cold spray powders. In addition, materials properties data is a backbone of this book because the advanced cold spray materials have proven to be comparable to wrought and enable cold spray to be incorporated into structural applications for near-net shape parts production as well as for repair.

Finally, numerous modern applications of cold spray representative of the Electronics, Medical, Petrochemical, Nuclear, Aerospace, Automotive, and Additive Manufacturing industries are presented.

Cover image
Title page
Table of Contents
Copyright
List of contributors
Preface
1. Introduction
2. The development of the cold spray process
2.1. Pre-1980 work
2.2. The development of modern cold spray
2.3. Recent theoretical and experimental cold spray research
2.4. Commercial systems development
2.5. Applications development
2.6. Some comments on the patent situation
3. Comparing cold spray with thermal spray coating technologies
3.1. Introduction
3.2. Traditional thermal spray technologies
3.3. Comparison of cold spray with traditional thermal spray
3.4. Conclusions
4. Cold spray economics
4.1. Introduction
4.2. Cold spray basics—calculating gas and powder costs
4.3. Cold spray systems, infrastructure, and workforce
4.4. Summary
5. Process parameters and control
5.1. Introduction
5.2. Cold spray process
5.3. Operating principles of the CS process
5.4. Bonding criteria
5.5. Gas dynamic models
5.6. Process variables
5.7. Process qualification and quality control methods
6. Studies of single-particle impact
6.1. Introduction
6.2. Characteristics of single-particle impact
6.3. Applications
6.4. Advances in numerical modeling with single-particle characterizations
6.5. Perspectives
7. Bonding mechanisms in cold spray
7.1. Solid-state bonding
7.2. What provides the conditions for solid-state bonding in cold spray?
7.3. Adiabatic shear instability
7.4. Jetting: a shock-induced phenomenon
7.5. Surface oxide and hydroxide effects
8. Cold spray equipment
8.1. Introduction
8.2. A brief history of cold spray equipment development
8.3. Cold spray system description
8.4. Cold spray system components
8.5. Auxiliary equipment
9. Characterization of cold-sprayed material consolidations
9.1. Advanced microscopy
9.2. Nanoindentation and micromechanical testing
9.3. Micropillar compression and microtensile testing
9.4. Macrohardness and instrumented indentation testing
9.5. Profilometry-based indentation plastometry
9.6. Surface roughness and topography
9.7. Mechanical properties and damage mechanisms of cold-sprayed light metals
10. Cold spray particle deposition for improved wear resistance
10.1. Introduction
10.2. Objective
10.3. Materials and methods
10.4. Modeling methods
10.5. Cold spray equipment and technology
10.6. Modeling and characterization methods
10.7. Results and discussion
10.8. Powder commercialization
11. Applications of cold spray
11.1. Introduction
11.2. Variety of applications
11.3. Repair of B-1 bomber forward equipment bay panels
11.4. B-1 bomber hydraulic lines
11.5. AH-64 static mast support
11.6. Periscope repair
11.7. Insulated gate bipolar transistor baseplates
11.8. Through-hole repairs of magnesium gearbox housings
11.9. Planetary gear shaft from a power shovel repair
11.10. Freeform cold spray additive manufacturing
11.11. Manufacturing at the point of need
11.12. Camouflaged SPEE3D printer
11.13. Repair of stainless steel nuclear waste canisters
11.14. Mobile robotic repair of large radioactive waste storage systems
12. The use of cold spray coating for corrosion protection
12.1. Introduction
12.2. Cold spraying of metals as a coatings technology for corrosion control
12.3. Galvanizing of steel structures to prevent corrosion
12.4. Preventing aqueous and hot-surface corrosion
12.5. Conclusions
13. Repair of magnesium components by cold spray techniques
13.1. Introduction
13.2. Problems in using magnesium components
13.3. Limitations of current technologies
13.4. Key issues in using the cold spray process
13.5. Developing and testing cold spray coating of magnesium
13.6. Cold spray technology for coating magnesium
13.7. Predictive modeling for process optimization
13.8. Cold spray trials
13.9. Coating characterization
13.10. Cost savings and implementation
13.11. Conclusions
14. Advances in cold spray additive deposition
14.1. Introduction
14.2. Deposition of functional coatings and materials
14.3. Machine learning, statistical, and data-driven analysis
14.4. Refined insights into bonding mechanisms
14.5. Powder and feedstock preprocessing
14.6. Nondestructive evaluation for cold spray
Index

Victor K. Champagne

Dr. Victor K. Champagne, Jr., FASM is recognized internationally as one of the foremost authorities on Cold Spray. He has held numerous positions throughout his career at the US Army Research Laboratory , Aberdeen Proving Ground, Maryland, USA. In his 36 years of materials research and development experience, he has been responsible for the advancement of emerging technologies for the Department of Defense. One of his most significant achievements, was the establishment of the ARL Cold Spray Center, which he led for over twenty years, and is devoted toward research, development and implementation of Cold Spray. Dr. Champagne has over 100 journal publications and 13 patents in cold spray technology. Currently, he is continuing to make extraordinary advances in Additive Manufacturing and the transition of technology into commercial applications. Working closely with industry, research institutes and academia his ideas have been translated into practical use and transitioned into the commercial sector and his achievements have been recognized across the globe.

Affiliations and expertise

US Army Research Laboratory, USA

Dennis Helfritch

Affiliations and expertise

Mark E. Schlesinger, P.E., FASM; Professor of Metallurgical Engineering; Department of Materials Science and Engineering; Missouri University of Science and Technology, USA

Mostafa Hassani

Mostafa Hassani-Gangaraj is an Assistant Professor jointly within the Sibley School of Mechanical & Aerospace Engineering (MAE) and the Department of Materials Science and Engineering (MSE) at Cornell. Prior to that, he completed a Senior Research Associate and Lecturer appointment at Cornell, a Post-doctoral appointment at MIT, and a PhD degree at Politecnico di Milano. His research interests lie at the intersection of solid mechanics, structural materials and additive manufacturing. Mostafa is particularly focused on understanding the behavior of materials under extreme conditions and solid-phase processing of materials.

Affiliations and expertise

Assistant Professor, Sibley School of Mechanical and Aerospace Engineering, Department of Materials Science and Engineering, Cornell University, USA

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Advances in Cold Spray

A Coating Deposition and Additive Manufacturing Process

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Victor K. Champagne

Dennis Helfritch

Mostafa Hassani