Cold Spray Additive Manufacturing

Abstract

Additive manufacturing (AM) is a novel manufacturing process of building a three-dimensional (3D) component by adding the materials layer by layer. AM facilitates design freedom by printing the complex geometries with precise dimensional accuracy. Initially, it originated as a rapid prototyping technique for the visualization of a real product and then upgraded to manufacture the actual products based on polymer materials. Polymer-based AM is usually called 3D printing and has been evolved as metal-based AM. The metallic AM realized the possibility of manufacturing the critical metal-based components of the aerospace, aeronautical, and defence sectors. Metal AM could be achieved with laser and electron beam technologies. Selective laser sintering, selective laser melting, direct metal deposition, and electron beam melting are the currently available technologies for 3D printing of metallic materials. Design for manufacturing improves productivity and reduces the lead time. Design for manufacturing concept can be applied to AM to support the design freedom and minimizes the usage of the materials. The design for AM (DfAM) is a new guideline to design products for effective AM. This section explores and discusses the DfAM principles for the cold spray AM (CSAM) process. The current industrial applications of the CSAM section present the current scenario of a wide spectrum of industrial usage of CSAM technology. The future scope and challenges of the CSAM section extensively review the scope of this technology in new arenas like biomedical applications and space research. This chapter presents the existing constraints of this technology and tries to provide possible solutions.