Powder Properties and Processing Conditions Affecting Cold Spray Deposition

Alessio Silvello,Irene G Cano,Pasquale Daniele Cavaliere,Sergi Dosta,Ana Martos,Vicente Albaladejo

doi:10.3390/coatings10020091

Abstract

The cold spray coating properties and performances are largely affected by feedstock characteristics and the employed processing parameters. Starting from experimental results obtained from the bibliographic data, the relationships between starting particles, processing conditions, and coating properties obtained by cold gas spray were analyzed. The relationships among these properties and particle velocity were described for various material systems. The effect on particle flattening, hardness, and porosity were largely described. Finally, the influence of the different parameters on the process output and on the coating properties was analytically defined through the employment of the multi-objective simulation tool modeFRONTIER. The analysis of data from the bibliography is a new trend that can also be applied to cold spray in order to analyze the effect of powder properties and spraying parameters on the cold spray (CS) process.

Highlights

Cold spray (CS), developed and studied over the last 15 years, has been established as a very powerful additive manufacturing technology for coatings or bulk production [1]
The aim of this study was to obtain the simple correlation between the impact particle velocity and all the spraying parameters affecting in-flight particle behavior
Bibliographic data were employed to build a database to be analyzed through a multi-objective optimization software to develop a provisional simple model capable of simulating the coating properties as a function of different processing parameters

Summary

Introduction

Cold spray (CS), developed and studied over the last 15 years, has been established as a very powerful additive manufacturing technology for coatings or bulk production [1]. The first impacting particles adhere to the substrate; in the following step, a coating layer is grown due to the further adhesion of particles to this first layer of adhered particles [3]. In both steps, different microstructural mechanisms, such as atomic and metallurgical bonding as well as interparticle cohesion, are a consequence of the severe plastic deformation and adiabatic shear instability of particles experienced during the impact. It is widely accepted that adhesion of the sprayed particles to the substrate is due to the phenomenon of heteroepitaxy (one kind of crystal is grown upon the surface of a different type) and adiabatic shearing

Objectives

Results

Conclusion