High Deposition Efficiency Research Articles

Investigation on ash deposition formation during co-firing of coal with wheat straw

Co-firing with coal is a promising technology for alleviating the ash-related issues during biomass combustion. This paper examines the effects of co-firing coal and straw on deposition characteristics under various biomass fractions and illustrates the mechanism of deposition formation during co-firing. Deposition experiments were conducted on a drop tube furnace with an air-cooled probe simulating the surface of the superheater. To clarify the detailed formation process of deposition, the micromorphology of deposits collected at different depths along the perpendicular direction to the deposition probe, as well as the elemental composition and mineralogy were characterized by SEM/EDS, XRF and XRD. Results showed that co-firing with coal reduced the serious slagging observed during biomass combustion, whereas resulted in higher deposition efficiency than that occurred in unblended coal/biomass combustion. As biomass fractions increased, the deposition efficiency exhibited a non-monotonic downward trend, whereas the sintering degree intensified remarkably. The formation of Ca sulfates and Fe-AAEMs aluminosilicates during co-firing led to the enrichment of Ca, S, Al, and Fe in deposits, and thus promoted melt-induced agglomeration. Viscous particles and adhesive films rich in alkali sulfates adhered closely to the probe surface were believed to be the initial layer, which triggered the deposition formation during co-firing. The inner layer composed of low-melting particles accelerated the formation and growth of deposition. Meanwhile, the fusion characteristics of coarse particles in the outer layer dominated the sintering degree. Co-firing with coal greatly alleviated the slagging tendency compared with biomass combustion, but we should be aware of the negative glue effect of AAEMs sulfates.

Exploring a novel panel-core connection method of large size lattice sandwich structure based on wire arc additive manufacturing

Large size sandwich structure is involved in a wide range of applications, such as aerospace and ship. However, the weak connection between panel and lattice is the bottleneck problem restricting their application. To solve this problem, this work demonstrates a novel circular scanning connection method based on pulse hot-wire arc additive manufacturing (PHWAAM) to connect the centimeter-scale and meter-scale panel. This method exhibits great connection quality (without unmelted holes) and high efficiency (about 60 s for each connection). The optimized process is studied, based on systematical analysis of the microstructure, the macro defects, and the compression testing results. By comparing and analyzing three different connection modes, the optimized circular scanning process has the advantages of low heat input and high deposition efficiency. It can be observed from the microstructure that there are equiaxed crystals and short columnar crystals in the connection area. The width of acicular α phase is finer than that of other processes, which is conducive to improving the mechanical properties. The connection area of the circular scanning process has a better matching of strength and plasticity through the compression test. Finally, the proposed connection method is also applicable to fabricate multi-cell lattice sandwich structure.

An overview of various applications of cold spray coating process

Cold spray (CS) coating process is emerging spray coating technology, used in different sector owing to its unique features. This technique has the capability to form dense deposits with very low oxygen content, no grain growth, high deposition efficiency, no oxidation, high deposition rate, solid-state process (low temperature), ultra thick coating, high bond strength, low porosity and phase changes. In addition, this technique provides numerous technological benefits over thermal spray technique because it utilizes kinetic energy (K.E.) rather than thermal energy (T.E.) for deposition. Further, range of materials including metals, ceramics, composites and even polymers can be sprayed by cold spray coating techniques. Due to these attractive properties of cold spray, this technique finds wide application in different sectors. Hence the aim of this paper is to give an overview of cold spray techniques and to summarize the various coatings deposited by distinct researchers in distinct sectors.

Cold Spray Additive Manufacturing: Microstructure Evolution and Bonding Features

ConspectusMost metal additive manufacturing (AM) methods involve the melting or sintering of feedstock powder or wire using an energy source (laser, electron beam, or electric arc). Solid-state AM, sometimes also known as non-beam-based AM, is a process in which the deposited material does not melt and is built up layer-by-layer, typically through severe plastic deformation. Initially considered to be a coating technique, by virtue of its high deposition rate, cold spray additive manufacturing (CSAM) is attractive as a solid-state AM technology. In the CSAM process, metal powder particles are impacted onto a substrate at a supersonic velocity and relatively low temperature. The CSAM process reduces or eliminates many problems associated with melting or beam-based AM methods, making the CSAM technically attractive for a wide range of applications, such as in the aerospace, automobile, marine, biomedical, machinery, and energy sectors.In this Account, the author briefly reviews the setup of a cold spray system and discusses the strengths and drawbacks of CSAM compared with thermal sprays and beam-based AM processes, as well as applications in relevant industries. The author summarizes the bonding mechanisms proposed for the cold spray process. The focus of this Account is to review the microstructure evolution of several typical model metals (copper, nickel, aluminum, and titanium) during the cold spray process. The author shows a large variety of microstructure characteristics (recrystallized grains, annealing twins, shear bands, submicron-sized grains, deformation twins, and nanometer-sized grains) in cold-sprayed copper, dynamic recrystallization of cold-sprayed nickel, and the formation of refined grains even below 10 nm in size in cold-sprayed aluminum. The magnitude of the stacking fault energy of as-sprayed materials considerably influences the microstructure after cold spray and postprocessing. Due to the relatively low thermal conductivity and ductility of titanium, cold spraying of titanium shows both a high deposition efficiency and relatively high porosity of as-sprayed parts, as well as a heterogeneous microstructure. Moreover, the Account introduces the postprocessing heat treatment and nanoindentation characterization of cold-sprayed materials. A fundamental understanding of microstructure evolution during and after the cold spray process is essential for optimal mechanical properties. Lastly, the author provides a perspective on applying old lessons and taking advantage of new techniques and materials, including powder characterization, hybrid additive manufacturing, machine learning for searching process windows, nanomechanical testing, and emerging alloys (high-entropy alloys, nanocrystalline alloys, and quasicrystals), to advance the research and applications of CSAM.

A Review on the Wear, Corrosion and High-Temperature Resistant Properties of Wire Arc-Sprayed Fe-Based Coatings.

Among different thermal spraying methods, arc-spraying has been widely used due to its low operating costs and high deposition efficiency. The rapid progress of cored wire technology in arc-spraying has increased possibilities for the preparation of new Fe-based coating materials with enhanced properties by adding reinforcement particles and alloying elements to suit the different applications. Fe-based coatings have been extensively used because of their high strength, toughness, lower production costs, and availability of raw materials. This makes them suitable replacements for Ni-based coatings in ambient and high-temperature applications. This review discusses the research status and developments of the arc-sprayed Fe-based coatings. The study specifically reviews the wear behavior, corrosion analysis, and high-temperature resistant properties of arc-sprayed Fe-based coatings, aiming to develop an understanding of the protection mechanisms for Fe-based coatings. The performance of the Fe-based coatings depends on the integrity of the coating structure. Optimizing arc-spraying parameters minimizes defects (pores, grain boundaries, unmelted particles, oxides, and microcracks) that deteriorate the coating properties. High amorphous phase content, ceramic reinforcement particles and alloying elements enhance the corrosion, tribological, and high-temperature resistant properties of Fe-based coatings. In high-temperature applications, Fe-based coatings form oxide scales that protect the coating from further oxidation; thus, it is important to select the optimum composition for the alloying elements.

Experimental investigation and parameter optimization of Cr2O3 atmospheric plasma spray nanocoatings

In this research, Cr2O3 ceramic nano-sized powder particles were prepared using ball milling and then were granulated to reach the proper size for spraying. Afterward, Cr2O3 nano-coatings were deposited by atmospheric plasma spraying (APS) process onto stainless steel substrates. To optimize APS parameters, spraying was carried out under six conditions with different parameters. Microstructures of the elemental/milled powder and coatings were characterized via a field emission scanning electron microscope (FESEM) equipped with energy-dispersive spectroscopy (EDS). In this research, Cr2O3 coatings were deposited under different spraying conditions to understand the effect of APS parameters on the splat formation, deposition efficiency, and porosities of the coatings. After parameter optimization, spraying was performed under a high deposition efficiency of 46.0±1.3%. The optimized Cr2O3 coatings showed porosity content, Knoop microhardness, and adhesive strengths of 8.7±2.2%, 823±27 HK0.2, and 49±4 MPa, respectively; making them a good candidate for industrial use.

Self-Adaptive Control System for Additive Manufacturing Using Double Electrode Micro Plasma Arc Welding

Wire arc additive manufacturing (WAAM) has been investigated to deposit large-scale metal parts due to its high deposition efficiency and low material cost. However, in the process of automatically manufacturing the high-quality metal parts by WAAM, several problems about the heat build-up, the deposit-path optimization, and the stability of the process parameters need to be well addressed. To overcome these issues, a new WAAM method based on the double electrode micro plasma arc welding (DE-MPAW) was designed. The circuit principles of different metal-transfer models in the DE-MPAW deposition process were analyzed theoretically. The effects between the parameters, wire feed rate and torch stand-off distance, in the process of WAAM were investigated experimentally. In addition, a real-time DE-MPAW control system was developed to optimize and stabilize the deposition process by self-adaptively changing the wire feed rate and torch stand-off distance. Finally, a series of tests were performed to evaluate the control system’s performance. The results show that the capability against interferences in the process of WAAM has been enhanced by this self-adaptive adjustment system. Further, the deposition paths about the metal part’s layer heights in WAAM are simplified. Finally, the appearance of the WAAM-deposited metal layers is also improved with the use of the control system.

Cold spray coating of PEEK surface by copper deposition: Interfacial adhesion at high deposition efficiency and bonding strength

Copper metallization of PEEK were performed by high-pressure cold spraying (HPCS) to obtain a high deposition efficiency (DE). Cu/PEEK interface and Cu/Cu interface produced under the same HPCS deposition conditions were compared in terms of feature and bonding strength. The DE of the Cu/Cu combination is 73% whereas the Cu/PEEK case gives a DE of 79%. These DE values are comparable whereas the bonding strengths are very different. The Cu/Cu interface reached values of 30−50 MPa while the Cu/PEEK interface was less resistant (0.2−10 MPa). SEM observations of the fracture surfaces exhibit the differences between these two combinations. The particles were less deformed and showed apparent decohesion for the Cu/PEEK case. In addition, craters due to particles decohesion and rebound were observed whereas the Cu/Cu case showed more particle flattening. The Cu/PEEK debonding was characterized by an adhesive failure. The copper powders that penetrated the PEEK substrate came out leaving craters. In addition, the weakly bonded Cu/Cu particles within the Cu/PEEK interface were conducive to a rupture. These features explain the low bonding strength of the Cu/PEEK interface. In case of Cu/Cu combination, the interface breaks by cohesive failure and the fracture surface evidenced flattened particles within the deposit. The greater adhesion strength of the Cu/Cu interface is then due to a more plastic deformation produced during the inter-collision of Cu powders during the HPCS deposition.

Metallization of polymers by cold spraying with low melting point powders

Polymers and polymer composites have been increasingly used due to their low density and high specific strength; however, their low electrical conductivity has limited their further application. Cold spray has recently been proven to be a feasible approach to metallize polymers. Previous results have shown that tin can be cold sprayed onto polymeric substrates when spraying with a low-pressure cold spray system at gas temperatures close to the melting point of tin. The successful deposition of tin was partly attributed to the tin reaching its incipient melting point. In this work, three low melting point metal powders, namely, Sn, Sn-Zn alloy, and Sn-Bi alloy, were cold sprayed onto five widely used engineering polymers . Different combinations of gas temperature and gas pressure were assessed. Results show that decreasing the melting points of the feedstock powders can improve their deposition efficiency on polymeric substrates, due to a higher degree of particle melting. Among the five polymers, the high-toughness ultra high molecular weight polyethylene and polycarbonate were relatively difficult to metallize. • SnZn and SnBi powders with lower melting points than Sn were cold sprayed on polymeric substrates. • Five common engineering thermoplastic polymers (ABS, Nylon, PC, PE, and PP) were metallized using low melting point powders. • Particle melting facilitated the deposition and inter-particle bonding, resulting in high deposition efficiency. • SnBi coatings exhibit higher adhesion to ABS than Sn when spraying at 300°C and 60 psi.

Residual stress in electrical discharge coatings

Abstract Electrical discharge coatings (EDC) can be applied on complex metal components to repair or act as protective coatings. A variant of the EDM process, it can be used to make coatings up to several mm thickness on electrically conductive substrates using sacrificial electrodes. The technology can be classified under thin EDC which is a surface modification process or thick EDC, also known by the commercial name “MSCoating”, which is a surface coating process. Inclusion of a high current pulse in the discharge waveform results in high deposition efficiencies of between 40 and 200 μm/min, with a subsequent decrease in energy into the coating per volume of material resulting in reduced re-melting of deposited material; the thermal shrinkage phenomenon seen in standard EDM recast layers is not as significant here. This results in thick EDCs with consistent tensile residual stresses of between +70 and + 100 MPa. Exclusion of the high current pulse reduces the deposition efficiency to between 0.5 and 10 μm/min. The subsequent increase in energy into the coating increases the melting and quenching of material, resulting in a more nanostructured or amorphous layer. This results in thick EDCs with largely compressive residual stresses, with a range of between +6 and −140 MPa, explained by amorphisation induced volume expansion. In cases where the deposition efficiency is sufficiently low, below 0.1 μm/min, increased melting and quenching of coating material results in high tensile residual stresses due to the thermal expansion mismatch between the layer and substrate. This results in thin EDCs with average tensile residual stresses of between +440 and +490 MPa. It is proposed that the changeable and controllable directionality of the residual stress within these coatings is a positive attribute, ultimately allowing tailorable coatings with regions of favourable residual stress dependent on final application, e.g. for wear or fatigue.

Deposition of ambient particles in the human respiratory system based on single particle analysis: A case study in the Pearl River Delta, China

It is important to evaluate how ambient particles are deposited in the human respiratory system in view of the adverse effects they pose to human health. Traditional methods of investigating human exposure to ambient particles suffer from drawbacks related either to the lack of chemical information from particle number-based measurements or to the poor time resolution of mass-based measurements. To address these issues, in this study, human exposure to ambient particulate matter was investigated using single particle analysis, which provided chemical information with a high time resolution. Based on single particle measurements conducted in the Pearl River Delta, China, nine particle types were identified, and EC (elemental carbon) particles were determined to be the most dominant type of particle. In general, the submicron size mode was dominant in terms of the number concentration for all of the particle types, except for Na-rich and dust particles. On average, around 34% of particles were deposited in the human respiratory system with 13.9%, 7.9%, and 12.6% being distributed in the head, tracheobronchial, and pulmonary regions, respectively. The amount of Na-rich particles deposited was the highest, followed by EC. The overall deposition efficiencies of the Na-rich and dust particles were higher than those of the other particle types due to their higher efficiencies in the head region, which could be caused by the greater sedimentation and impaction rates of larger particles. In the head region, the Na-rich particles made the largest contribution (30.5%) due to their high deposition efficiency, whereas in the tracheobronchial and pulmonary regions, EC made the largest contribution due to its high concentration. In summary, the findings of this initial trial demonstrate the applicability of single particle analysis to the assessment of human exposure to ambient particles and its potential to support traditional methods of analysis.

An investigation for airflow and deposition of PM2.5 contaminated with SAR-CoV-2 virus in healthy and diseased human airway

This study is motivated by the amplified transmission rates of the SAR-CoV-2 virus in areas with high concentrations of fine particulates (PM2.5) as reported in northern Italy and Mexico. To develop a deeper understanding of the contribution of PM2.5 in the propagation of the SAR-CoV-2 virus in the population, the deposition patterns and efficiencies (DEs) of PM2.5 laced with the virus in healthy and asthmatic airways are studied. Physiologically correct 3-D models for generations 10–12 of the human airways are applied to carry out a numerical analysis of two-phase flow for full breathing cycles. Two concentrations of PM2.5 are applied for the simulation, i.e., 30 μg⋅m−3 and 80 μg⋅m−3 for three breathing statuses, i.e., rest, light exercise, and moderate activity. All the PM2.5 injected into the control volume is assumed to be 100% contaminated with the SAR-CoV-2 virus. Skewed air-flow phenomena at the bifurcations are proportional to the Reynolds number at the inlet, and their intensity in the asthmatic airway exceeded that of the healthy one. Upon exhalation, two peak air-flow vectors from daughter branches combine to form one big vector in the parent generation. Asthmatic airway models has higher deposition efficiencies (DEs) for contaminated PM2.5 as compared to the healthy one. Higher DEs arise in the asthmatic airway model due to complex secondary flows which increase the impaction of contaminated PM2.5 on airways’ walls.

REVIEW OF APPLICATION AND RESEARCH BASED ON COLD SPRAY COATING MATERIALS

Cold spray technology is an advanced spray technology, and its technical principle is the same as that of additive manufacturing technology. Cold spraying technology combines multiple advantages in the spraying field: not only can the deposition of thick coatings be achieved, but the coatings prepared by this technology have the characteristics of high density, low oxygen content, good mechanical properties of the coating surface, and high deposition efficiency. Cold spraying technology can prepare corrosion-resistant coatings, high-temperature resistant coatings, wear-resistant coatings, conductive coatings, anti-oxidation coatings, and other functional coatings. After decades of development and exploration, cold spraying technology is preparing metal coatings. The application is very wide and the process is mature; the same cold spray technology can also prepare non-metallic coatings. Mainly to immerse repair and protect the surface of metal alloy parts and a small part of non-metal parts, so that these parts have better mechanical properties and mechanical behavior. This article mainly reviews the application of cold spray technology in the field of spray materials and summarizes the existing conventional metal series, rare metal series and non-metal material, conventional non-ferrous metals: copper, titanium, aluminum and nickel. Metal materials are currently widely used in the field of cold spraying. Among them, titanium-based metals restrict their applications due to their own properties; rare metals: tungsten, tantalum, and niobium-based metal materials. The application of rare metals in cold spraying is still in its infancy stage; non-metallic materials: polymer materials and ceramic powder materials, non-metallic materials have the characteristics of surface modification and strengthening technology, but also have low oxygen content, low thermal stress, high density, good bonding strength, in the deposition process and the substrate will not change the advantages of physical organization structure. Finally, the existing problems of rare metal materials and non-metal materials are raised.

Synthesis of Al-Doped ZnO Films Assisted with Hollow-Cathode Glow Discharge and Their Characterization

Transparent conductive oxides, such as aluminum-doped zinc oxide (AZO), are of substantial importance for use in a broad range of applications because of their excellent optical and electrical properties. AZO film can be deposited by using several conventional techniques, although they suffer from limitations such as long deposition time, high cost, and the requirement for complex deposition equipment. Here, we used hollow-cathode glow discharge, which produces a high-density plasma and achieves high deposition efficiency. Remarkably, instead of metallic target materials, we used Al2O3 and ZnO powders filled in the hollow cathode as a target, thus avoiding the need for specifically designed targets in this technique. The films were deposited using mixtures of argon and oxygen at various ratios (0% to 50% oxygen), to improve the film characteristics. The films deposited under all conditions exhibited hexagonal wurtzite ZnO structure, while the grain size increased with increasing oxygen content. The film was thick and porous when using low oxygen content, but became thin and dense with increasing oxygen content. The optical transmittance was found to be strongly dependent on the processing gases used, with the highest transmittance of 84% being attained when using 25% oxygen gas. The bandgap of the films lay between 3.27 eV and 3.33 eV. The highest carrier concentration and mobility were attained when using 25% oxygen, and the Hall resistivity decreased with increasing oxygen content. Besides the excellent transmittance and electrical properties of the deposited films, it is expected that the results of this study will be useful for solar cells and optoelectronic applications due to the relatively low cost of this technique and the lack of specific target requirements.

Deposition of tungsten coatings by detonation spraying

Tungsten is a promising material for plasma-facing components of thermonuclear reactors. In the present work, tungsten coatings of low residual porosity (1%) were deposited on copper substrates by detonation spraying. Calculations of the particle temperatures and velocities were conducted for tungsten particles of different sizes using a previously developed model. These calculations helped selecting the spraying parameters enabling the formation of high-quality tungsten coatings in the experiments. A proper selection of the stand-off distance allowed achieving a high deposition efficiency of the powder (60%). The coatings showed a high bonding strength to the copper substrates, which was found to be 100 MPa, and a high hardness (850 HV). The coatings were shown to accumulate compressive stresses, which are beneficial for the structural integrity of coatings up to 500 μm thick.

Effect of magnetic Field on the microstructure and mechanical properties of inconel 625 superalloy fabricated by wire arc additive manufacturing

• The magnetic field has been applied during the Wire Arc Additive Manufacturing (WAAM) processing of Inconel 625 . • The mechanism that the effect generated by magnetic field on the microstructure was discussed. • The application of magnetic fieldeffectively improves the mechanical properties of WAAM Inconel 625 alloy. Wire Arc Additive Manufacturing (WAAM) technology for Inconel 625 alloy is increasingly being considered for its high deposition efficiency, low cost and flexible manufacturing capability. However, very high heat input and severe elemental segregation during additive manufacturing process reduces the forming quality of Inconel 625 alloy and degrades its performance. In this work, magnetic field has been applied during the Cold Metal Transfer (CMT) WAAM processing of Inconel 625 to modify its microstructure. The effect of the magnetic field applied during the CMT-WAAM process on the microstructure and mechanical properties of Inconel 625 alloy has been studied. Results show that: (i) the stirring effect of the magnetic field during the deposition process refines dendritic crystal size and (ii) the convection generated by the magnetic field promotes diffusion of elements such as Nb and Mo in the melt pool, thereby inhibiting segregation. Evaluation of the mechanical properties of the Inconel 625 alloy deposited under magnetic field shows an increase in its hardness, yield strength (∼13 %), ultimate tensile strength (UTS) and elongation. From the work, it is evident that the application of magnetic field during CMT-WAAM process, refines the dendritic crystals, suppresses segregation, and effectively improves the mechanical properties of Inconel 625 alloy.

Limiting regimes for electron-beam induced deposition of copper from aqueous solutions containing surfactants

Focused electron beam induced deposition of pure materials from aqueous solutions has been of interest in recent years. However, controlling the liquid film in partial vacuum is challenging. Here we modify the substrate to increase control over the liquid layer in order to conduct a parametric study of copper deposition in an environmental scanning electron microscope. We identified the transition from electron to mass-transport limited deposition as well as two additional regimes characterized by aggregated and high-aspect ratio deposits. We observe a high deposition efficiency of 1–10 copper atoms per primary electron that is consistent with a radiation chemical model of the deposition process.

Preparation and properties of supersonic atmospheric plasma sprayed TiB2−SiC coating

Abstract With the TiB2−SiC powders after spray granulation and vacuum calcination as raw materials, the TiB2−SiC coating was prepared by supersonic atmospheric plasma spraying (SAPS). The effects of spraying power and spraying distance on the properties of the TiB2−SiC coating were investigated and the fabrication processing of SAPS was optimized. The results show that the sprayed powders after calcination have a uniform particle size distribution, good sphericity and enhanced fluidity. The coating prepared by the calcined powders has a dense structure and high deposition efficiency. When the calcined TiB2−SiC powders are used and the spraying power is 95 kW and the spraying distance is 150 mm during supersonic plasma spraying, the obtained TiB2−SiC coating behaves the best comprehensive performance with the porosity, microhardness, bonding strength and resistivity equal to 5.6%, 3.57 GPa, 18.3 MPa and 10.8 mΩ·cm, respectively.

Finite element analysis of effects of dynamic preheating on thermal behavior of multi-track and multi-layer laser cladding

Laser cladding technologies has received wide attention since its low dilution and high deposition efficiency. However, the high cooling rate and the temperature gradient due to the rapid heating and cooling characteristic could cause excessive thermal stress and even crack in the coating. In this paper, a dynamic preheating method, in which an additional heat source is applied to heat the localized region ahead of the moving molten pool, was proposed with the intent of solving these problems. A three-dimensional finite element model was established to explore the effect of the dynamic preheating on the thermal behavior of the multi-track and multi-layer laser cladding. The laser cladding experiment was performed to verify the accuracy of the heat transfer model. The simulated thermal cycle curves are in agreement with the experimental thermal history. The calculated results show that the temperature gradient in the depth direction and the cooling rate decrease with the increasing layers. The appropriate process parameter, such as thermal flux density, interaction time, and preheating distance leads to the decrease of the cooling rate and the maximum temperature gradient. Thus it is illustrated that dynamic preheating is contributed to the reduction of the thermal stress and the cracking probability.

Development of a high-speed laser material deposition process for additive manufacturing

Extreme high-speed laser material deposition (EHLA) is a variant of laser material deposition (LMD) with a modified powder gas jet focus. EHLA allows deposition at high process speeds in the range of several hundred meters per minute and the deposition of layers as thin as 25 μm. Feed rates can be in the range of 50 g/min or above. The processing of material combinations with poor weldability or different melting points is possible, with simultaneously smaller heat-affected zone and dilution zone compared to conventional LMD. Until now, EHLA has mainly been used for applying wear-resistant and corrosion-resistant coatings to rotationally symmetric parts, where high process speeds are achieved by rotation of the substrate. Developing EHLA for additive manufacturing (AM) aims at manufacturing highly individualized parts with high volume buildup rates and finer structural resolution compared to conventional LMD. The main steps toward harnessing EHLA for AM, termed EHLA 3D, are (a) process parameter development for volume buildup through deposition of multiple layers on top of each other and (b) the development of system technology that allows relative spatial movement between the powder nozzle and the substrate at high speeds and high accuracy in three dimensions. With a fast back-and-forth motion, high acceleration rates are necessary to ensure high volume buildup rates and high powder deposition efficiency. In this work, a specially designed tripod machine concept that has been developed in cooperation at Fraunhofer ILT is introduced. Theoretical considerations concerning achievable powder deposition efficiency as a function of process speed and acceleration of the handling system are presented. Furthermore, the results of process parameter development for up to 40 m/min with the iron-base alloy 1.4404 are shown. Virtually pore-free deposition of cuboid volumes is demonstrated. The mechanical values of the additively manufactured volumes are compared to the values for solution-annealed material, conventional LMD-manufactured samples, and samples produced by laser powder bed fusion (LPBF). Finally, an outlook on future research activities required for further development of EHLA 3D is given, covering system technology, buildup strategies, software integration, and possible applications of the new technology in repair, coating, and (hybrid-)additive contexts.