Cold Spray Additive Manufacturing
Cold Spray Additive Manufacturing
Cold Spray Additive Manufacturing (CSAM)
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Recent Efforts
- Gas Gun Experiments Reveal Thermal Response of Polymeric Materials
- Multi-physics Informs Cold Spray Research with Material Property Identification
- Cold Spray on to Advanced Composite Substrates
Unified Workflow for Informing Cold Spray Research
Gas Gun Experiments
Single Stage Light Gas Gun Overview
- Particle diameter from 3.175 mm to ~100 µm (with sabot)
- Up to 1000 m/s with helium
- -168 ºC to ~600 ºC particle temperature
Sabot Launching System
Gas Gun Experiments Reveal Thermal Response of Polymeric Materials
Features of deformation are visible at macro scales
Deformation history informs the effect of process parameters
Experiment-Integrated Multiphysics-Informed Materials Property Discovery
Benchtop Cold Spray Experiments
- Up to 120 psi (~8 bar) Nitrogen / Helium
- 500 ºC with 12 kW heater power
- Materials: Polymers, Metals, Composites
- Used to validate low pressure parameters
Low Pressure – Custom/Adapted Benchtop Cold Spray Systems
Cold Spray of/on to Advanced Composite Substrates
Polymer Metallization/Graded Deposits
"Checkerboard Effect" and Mitigation
Modeling of Cold Spray Impact Physics
Impact Velocity/Temperature
FEA of High Strain Rate Particle Impacts
Full-Scale Cold Spray Experiments
- Up to 1000 psi (~70bar) Nitrogen
- 800 ºC with 21 kW heater power
- Aluminum, Copper, Nickel, Steels
- Industrial-scale system with custom accessories
High Pressure – VRC Gen III Cold Spray System
