Residual Stress Distributions in Cold-Sprayed Copper 3D-Printed Parts
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Residual Stress Distributions in Cold-Sprayed Copper 3D-Printed Parts Rebecca Sinclair-Adamson1 • Vladimir Luzin2,3 • Andrew Duguid4 Krishnan Kannoorpatti1 • Rebecca Murray1
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Submitted: 14 November 2019 / in revised form: 16 March 2020 The Author(s) 2020
Abstract Cold-spray additive manufacturing (CSAM) builds strong, dense metal parts from powder feedstock without melting and offers potential advantages over alternatives such as casting, liquid phase sintering, laser or e-beam melting or welding. Considerable effort is required to relieve residual stresses that arise from melt/freeze cycling in these methods. While CSAM does not involve melting, it imposes high strain rates on the feedstock and stress anisotropies due to complex build paths. This project explores residual stress in two CSAM objects. The CSAM components were produced from 99% pure copper powder (D50 = 17 lm): (1) a cylinder ([ = 15 mm, height = 100 mm, weight = 145 g) and (2) a funnel (upper outer [ = 60 mm, lower outer [ = 40 mm, wall thickness = 8 mm, weight = 547 g). The non-heat-treated components were strain-scanned using a residual stress neutron diffractometer. Maximum residual stresses in any
direction were: tensile: 103 ± 16 MPa (cylinder) and 100 ± 23 MPa (funnel); compression: 58 ± 16 MPa (cylinder) and 123 ± 23 MPa (funnel). Compared to the literature, the tensile residual stresses measured in the CSAM components were lower than those measured in cast materials, laser or welding AM methods, and numerical modelling of cold-spray coatings, while within the wide range reported for measurements in cold-spray coatings. These comparatively low residual stresses suggest CSAM is a promising manufacturing method where high residual stresses are undesirable. Keywords additive manufacturing casting cold spray cold-spray additive manufacturing copper neutron residual stress
Introduction This article is part of a special topical focus in the Journal of Thermal Spray Technology on Advanced Residual Stress Analysis in Thermal Spray and Cold Spray Processes. This issue was organised by Dr. Vladimir Luzin, Australian Centre for Neutron Scattering; Dr. Seiji Kuroda, National Institute of Materials Science; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang, Swinburne University of Technology. & Rebecca Murray [email protected] 1
Advanced Manufacturing Alliance, Charles Darwin University, Ellengowan Drive, Casuarina, NT 0810, Australia
2
Australian Nuclear Science and Technology Organization, Lucas Heights, NSW 2234, Australia
3
School of Engineering, The University of Newcastle, Callaghan, NSW 2308, Australia
4
SPEE3D, Dandenong, VIC 3175, Australia
The principle of cold-spray (CS) manufacturing was established in the Soviet Union in the 1980s (Ref 1). When powder is sprayed towards a substrate, it can produce coatings. Powders suitable for cold spray include metals, some ceramics, and some polymers. In cold spray, powder is suspended in a hot, pressurised carrier gas. The carrier gas is heated not
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