Design of Residual-Stress-Compensating Molds for Cold Spray Additive Manufacturing Applications
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Design of Residual-Stress-Compensating Molds for Cold Spray Additive Manufacturing Applications Isaac M. Nault1
•
Gehn D. Ferguson1 • Victor Champagne1 • Aaron Nardi1
Submitted: 11 July 2019 / in revised form: 13 December 2019 Ó ASM International 2020
Abstract A methodical procedure for designing molds for cold spray additive manufacturing has been developed and validated. In a preliminary trial, a cold-sprayed part was shown to deform beyond the spatial tolerances of its defined shape. Based on these data and utilizing a linear elastic model of deformation, a new ‘‘compensated’’ mold with a modified shape was generated. The shape of the part deposited onto the compensated mold was measured to have, at maximum, approximately half the error as in the original trial, demonstrating the potential of such mold compensation as a means of achieving the final dimensional accuracy requirements of cold-sprayed parts. Keywords additive manufacturing cold spray linear elastic predictive modeling residual stress tool design
Introduction Cold spray (CS) is a solid-state powder consolidation process in which micron-sized powder particles are accelerated to supersonic velocities and impact upon a surface, This article is part of a special topical focus inthe Journal of Thermal Spray Technology on Advanced ResidualStress Analysis in Thermal Spray and Cold Spray Processes. Thisissue was organized by Dr. Vladimir Luzin, Australian Centre forNeutron Scattering; Dr. Seiji Kuroda, National Institute of MaterialsScience; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang,Swinburne University of Technology. & Isaac M. Nault [email protected]; [email protected] 1
CCDC Army Research Laboratory, FCDD-RLW-MD Weapons and Materials Research Directorate, Manufacturing Science and Technology Branch, Aberdeen Proving Ground, MD 21005, USA
gradually building up a deposit over time. Champagne (Ref 1) compiled a textbook documenting the basic science and uses of the CS process. Rokni et al. (Ref 2) presented a comprehensive review of advancements in CS technology in the decade from 2007. The bonding process in CS is kinetic energy driven. In a comparison of CS with thermal spray technologies, Smith (Ref 3) noted that one of its unique attributes is that the CS process does not rely on melting of the feedstock powder. With the exception of highly localized melting in some instances, the particles remain in the solid state for the entire duration of the process. Actually, Hassani-Gangaraj et al. (Ref 4) argued that such localized melting might hinder particle bonding. As a solid-state process, CS allows the production of deposits with ‘‘wrought-like’’ properties in the as-deposited condition accompanied by high deposition rates. Hassani-Gangaraj et al. (Ref 5) used a high-speed camera to capture single particle impacts as well as finite element modeling to show that, during impact, the particles experience intense compressional shock waves and extreme plastic deformation, which are ultimately argued to
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