Residual Stress Buildup in Ti Components Produced by Cold Spray Additive Manufacturing (CSAM)
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Residual Stress Buildup in Ti Components Produced by Cold Spray Additive Manufacturing (CSAM) V. Luzin1 • O. Kirstein2 • S. H. Zahiri3 • D. Fraser3
Submitted: 15 November 2019 / in revised form: 30 April 2020 Ó ASM International 2020
Abstract Cold spray has been developed recently to be used as an additive manufacturing technology in order to fabricate bulk components. Residual stresses are known to build up in coatings made by cold spray; therefore, cold spray additive manufacturing (CSAM) is also expected to generate residual stress in bulk parts and components, and that residual stress can lead to shape distortions or component cracking. The residual stress analysis has been applied to some generic sample shapes, a thick patch deposit and a vertical wall, produced by CSAM out of Ti powder. The residual stress mapping has been achieved using neutron diffraction technique and analyzed within a modeling approach. The analysis allowed it to be determined as to what were the major contributions into the overall stress field and to establish the main sources of the residual stress, providing an analytical tool for prediction of the residual stress buildup in more complex shapes. Keywords additive manufacturing cold spray processing properties residual stress
& V. Luzin [email protected] 1
Australian Nuclear Science and Technology Organisation, Lucas Heights, NSW 2232, Australia
2
European Spallation Source ESS, 223 63 Lund, Sweden
3
Commonwealth Scientific and Industrial Research Organisation, Clayton, Melbourne, VIC 3168, Australia
Introduction The majority of cold spray applications and research studies in the recent years have been focused mostly on production of coatings of different kinds, usually on flat or cylindrical surfaces (Ref 1). Especially when coatings are thin, such as in many corrosion protection applications, the extension into more complex surfaces is not extremely challenging and the approach is very similar to surface painting, though in this case with metal ‘‘paint,’’ metallization. More problems and challenges occur when thick deposits and complex 3D shapes are under consideration. Probably due to this, much lesser attention is paid to adopting the spraying technique to less trivial applications that can be called cold spray additive manufacturing (CSAM) (Ref 2–4). Among such applications are (1) the surface repair and dimensional tolerance restoration that deals with addition of material to the existing part instead of partial loss of the original material and (2) production of complex 3D parts by spraying that are fully made of the sprayed material. In both cases, the technological challenges are great because these require development of complicated robotic systems with strong support from the basic understanding of the cold spray process with multiple and intertwined processing parameters. These include gas pressure and temperature, nozzle geometry, powder type and characteristics, feed rate, traverse speed, traverse trajectory, spray angle, etc. As
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