Cold spray materials deposition process - Fundamentals and applications

Edited by Victor K. Champagne

Woodhead Publishing Limited, Publisher

2007

1 IntroductionV. K. Champagne, US Army Research Laboratory, USA

Part 1 General issues

2 The development of the cold gas-dynamic spray processA. Papyrin, Cold Spray Technology (CST), USA

2.1 History of cold spray2.2 Discovery of the cold spray phenomenon and its basic features2.3 Initial studies on development of cold spray. Basic physical principles and key features2.4 Evolution of cold spray technology and current status2.5 Some comments on the patent situation2.6 Symbol list2.7 References

3 Comparing cold spray with thermal spray coating technologiesM. F. Smith, Sandia National Laboratories, USA

3.1 Introduction3.2 Traditional thermal spray technologies3.3 Comparison of cold spray t o traditional thermal spray3.4 Conclusions3.5 References

4 The advantages and disadvantages of the cold spray coating processJ. Karthikeyan, ABS Industries Inc, USA

4.1 Introduction4.2 Advantages of the cold spray process4.3 Disadvantages of the cold spray process4.4 References

5 The economics of the cold spray processS. Celotto, J. Pattison, J. S. Ho, A.N. Johnson and W. O’Neill, Innovative Manufacturing Research Centre, UK

5.1 Introduction5.2 Cold spray equipment and infrastructure5.3 Consumables5.4 Comparison to other thermal spray techniques5.5 Comparison to other additive fabrication techniques

5.6 Conclusions and future trends5.7 Sources of further information and advice5.8 References

Part 2 Cold gas-dynamic spray process parameters

6 Powders in the cold spray processF. J. Brodmann, F. J. Brodmann & Co, USA

6.1 Introduction6.2 Selection criteria for cold spray feedstock6.3 Key powder properties6.4 Powder manufacturing process6.5 New material developments6.6 Discussion6.7 Conclusions6.8 Acknowledgements6.9 References

7 The influence of nozzle design in the cold spray processK. Sakaki, Shinshu University, Japan

7.1 Introduction7.2 Numerical simulation of cold spray process7.3 Nozzle design influences7.4 References

8 The role of particle temperature and velocity in cold spray coating formationT. Van Steenkiste, Delphi Systems, USA

8.1 Introduction8.2 Particle velocity and temperature8.3 The impact of particle velocity and temperature on coating formation8.4 Altering particle temperature8.5 Conclusions8.6 Acknowledgements8.7 References

9 Particle/substrate interaction in the cold spray bonding processM. Grujicic, Clemson University, USA

9.1 Introduction9.2 Transient non-linear dynamics analysis of the cold-gas particle/substrate interactions9.3 Adiabatic shear instability and plastic-flow localization9.4 The role of interfacial instability9.5 Conclusions9.6 References

10 Supersonic jet/substrate interaction in the cold spray bonding process

V. F. Kosarev, S. V. Klinkov and A. Papyrin, A. Papyrin, Cold Spray Technology (CST), USA

10.1 Introduction10.2 Investigation of supersonic air jet exhausting from a nozzle10.3 Impact of a supersonic jet on a substrate10.4 Heat transfer between a supersonic plane jet and a substrate under conditions of cold spray10.5 Symbol list10.6 References

11 Portable, low pressure cold spray systems for industrial applicationsR. Maev, V. Leshchynsky and E. Strumban, University of Windsor, Canada

11.1 State-of-art cold spray systems11.2 State-of-art powder feeding systems11.3 Modification of the low pressure portable GDS system11.4 Industrial low pressure portable GDS system11.5 References

12 Stationary cold spray systems for industrial applicationsH. Höll, Cold Spray Technology GmbH, Germany

12.1 Introduction12.2 Industrial cold gas spray equipment: system layout, gas supply and control cabinet12.3 Industrial cold spray equipment: gas heater, powder feeder and cold spray gas12.4 References

Part 3 Applications of cold gas-dynamic spray coatings

13 Mechanical, thermal and electrical properties of cold sprayed coatingsA. Gouldstone, W. B. Choi, W. Chi, Y. Wu and S. Sampath, State University of New York, USA

13.1 Introduction13.2 Materials used for analysis13.3 Mechanical property measurements13.4 Microstructural characterization of coatings13.5 Properties of coatings13.6 Comparison of cold-spray coatings with traditional thermal spray of coatings13.7 Conclusions13.8 Acknowledgements13.9 References

14 Cold spray particle deposition for improved wearT. Eden and D. Wolfe, Penn State University, USA

14.1 Introduction14.2 Current state of the art

14.3 Cold spray wear resistant material properties14.4 Cold spray wear resistant processing14.5 Characterization14.6 Powder characteristics14.7 X-ray diffraction (XRD) and phase analysis14.8 Scanning electron microscopy14.9 Tribology14.10 Adhesion and bond strength14.11 Potential hybrid process combining cold spray can laser processing14.12 Conclusions

15 The use of cold spray coating for corrosion protectionR. C. McCune, formerly Ford Motor Company, USA

15.1 Introduction15.2 Cold spraying of metals as a coatings technology for corrosion control15.3 Galvanising of steel structures to prevent corrosion15.4 Preventing aqueous and hot-surface corrosion15.5 Conclusions15.6 References

16 Electromagnetic interference shielding by cold spray particle depositionD. J. Helfritch, US Army Research Laboratory, USA

16.1Introduction16.2 Cold spray particle deposition16.3 Parameter screening16.4 Screening tests16.5 Application16.6 Conclusions16.7 Acknowledgements16.8 References

17 Repair of magnesium components by cold spray techniquesV. K. Champagne, US Army Research Laboratory, USA

17.1 Introduction17.2 Problems in using magnesium components17.3 Limitations of current technologies17.4 Key issues in using the cold spray process17.5 Developing and testing cold spray coating of magnesium17.6 Cold spray technology for coating magnesium17.7 Predictive modelling process optimization17.8 Cold spray trials17.9 Coating characterization17.10 Cost savings and implementation17.11 Conclusions17.12 References