Residual Stresses in Cold Spray Additively Manufactured Hollow Titanium Cylinders
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Residual Stresses in Cold Spray Additively Manufactured Hollow Titanium Cylinders Alejandro Vargas-Uscategui1 • Peter C. King1 • Mark J. Styles1 • Michael Saleh2 Vladimir Luzin2,3 • Kevin Thorogood2
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Submitted: 29 November 2019 / in revised form: 28 February 2020 Ó ASM International 2020
Abstract In cold spray additive manufacturing (CSAM), the severe plastic deformation of the input powder particles leads to an accumulation of residual stresses, the magnitude of which is affected by process conditions. In the current study, the effects of traverse speed and powder feed rate on the residual stress state were investigated in commercially pure titanium cylinders produced by CSAM. Residual stress measurements were made in a grid pattern covering the 2D cross section using the KOWARI neutron diffractometer at ANSTO, Australia, and selected results were validated using the contour method. It was found that the thermal effect was dominant on the residual stress state generating a tensile state near the inner and outer surfaces of the cylinder walls while compressive residual stresses tend to accumulate in the center of the wall. The residual stresses were dominated by thermal stresses at low traverse 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 organized 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.
Electronic supplementary material The online version of this article (https://doi.org/10.1007/s11666-020-01028-3) contains supplementary material, which is available to authorized users. & Alejandro Vargas-Uscategui [email protected] 1
CSIRO Manufacturing, Gate 5, Normanby Road, Clayton, VIC 3168, Australia
2
Australian Nuclear Science and Technology Organisation, Lucas Heights, NSW 2234, Australia
3
School of Engineering, The University of Newcastle, Callaghan, NSW 2308, Australia
speed, while peening becomes more critical at high traverse speeds. Increasing the powder feed rate increased the magnitude of the residual stresses. High traverse speeds and low feed rates are beneficial for producing 3D parts by CSAM. However, slow traverse speeds are more detrimental than high feed rates for a given layer thickness. Keywords additive manufacturing cold spray contour method neutron diffraction residual stress titanium
Introduction Cold dynamic gas spray is a solid-state deposition technique that allows the conversion of powder into a solid structure by projecting particles at supersonic speeds onto a solid surface (Ref 1). This deposition method has been widely used as a coating technique and for repair or reclamation of engineering components (Ref 2). The process can also be referred to as cold spray additive manufacturing (CSAM) due to the ability to build 3D objects when the
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