Abstract
The difficulty in significantly reducing the cost of titanium products is partly related to the high cost of manufacturing. This includes additive manufacturing; e.g. Electron Beam Melting (EBM) and Selective Laser Melting (SLM), as well as traditional approaches that are based on a melting process. In particular, the cost of titanium powder has placed limits on the application of additive manufacturing approaches that involve melting to broader commercial applications beyond military, aerospace and implants. More than a decade ago, Australia adopted cold spray technology as a meltless additive manufacturing technique to fabricate titanium through a strategic initiative at Commonwealth Scientific and Industrial Research Organisation (CSIRO). The high deposition rate, ~100 times faster than the other additive technologies, and the solid state deposition were amongst the rationales for investment in cold spray technology. A combination of carefully designed experiments and sophisticated 3D models were developed to assess performance of the current industrial-scale cold spray systems for commercial clients. The success and challenges of this solid state deposition technology will be detailed with a focus on real industrial impact. The future development of melt-less titanium manufacturing using cold spray will be discussed with consideration of commercial and environmental benefits.
Highlights
Rapid deposition of titanium solid particles without melting was an important rational for many forward looking companies to adopt cold spray additive technology in Australia and around the globe
The predicted heat transfer profiles revealed higher temperature at the tip of the Plasma Giken ® (PG) compared to the Innovation ® (II) system
The computed trajectory of particles velocity in the II system nozzle (Fig. 3a) revealed that titanium particles acceleration continued beyond the nozzle exit
Summary
Rapid deposition of titanium solid particles without melting was an important rational for many forward looking companies to adopt cold spray additive technology in Australia and around the globe. In recent years, this has created interests in Australian share market (ASX) through creation of companies such as Titomic Ltd with other companies such as RUAG Australia Pty Ltd and Kinetic Elements Pty Ltd using cold spray additive process. The model outcomes as a capability to compare the current industry scale cold spray systems performance is presented This capability has already been successfully examined at CSIRO to improve cold spray system design and to quantify the key processing parameters in regards to titanium additive manufacturing. An example of such application is presented with some highlights relevant to the real titanium industry
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