Toolpath planning for cold spray additively manufactured titanium walls and corners: Effect on geometry and porosity

Abstract

Cold spray additive manufacturing (CSAM) is a solid-state deposition process well-suited to titanium that has the potential to make large, near-net-shape parts at high productivity. However, further research is required to truly accomplish the freedom of design expected from CSAM and, in particular, to address how to manufacture a specific 3D object with minimal porosity. Therefore, this paper focuses on understanding how tool path planning strategy and robot kinematics affect the geometry and porosity distribution in a 3D object. Square titanium frames were manufactured layer-by-layer using a continuous tool path planning strategy in which the contour spray angle, traverse speed and corner smoothing radius were varied selectively. The sample geometry was analysed by 3D laser scanning, and the capacity to produce straight, vertical walls and square corners were demonstrated. The total porosity in the manufactured objects was measured using the Archimedes’ principle, further investigated by metallographic cross-section analysis, and then validated by X-ray computed tomography on selected samples. Porosity was distributed layer by layer, creating a fishbone structure in the cross-section with higher porosity between the layers and near the edges of the walls and corners. The influence of robot kinematics and toolpath planning on forming underbuilt and overbuilt structures and how they influenced porosity development are also discussed. The knowledge generated from this research can significantly influence the development of tool path planning strategies in CSAM, providing the means to produce improved near-net-shapes with controlled porosity formation.