Cold Spray in the Realm of Additive Manufacturing PDF
Preview Cold Spray in the Realm of Additive Manufacturing
Materials Forming, Machining and Tribology Sunil Pathak Gobinda C. Saha Editors Cold Spray in the Realm of Additive Manufacturing Materials Forming, Machining and Tribology Series Editor J. Paulo Davim, Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal This series fosters information exchange and discussion on all aspects of materials forming, machining and tribology. This series focuses on materials forming and machining processes, namely, metal casting, rolling, forging, extrusion, drawing, sheet metal forming, microforming, hydroforming, thermoforming, incremental forming, joining, powder metallurgy and ceramics processing, shaping processes for plastics/composites, traditional machining (turning, drilling, miling, broaching, etc.), non-traditional machining (EDM, ECM, USM, LAM, etc.), grinding and others abrasive processes, hard part machining, high speed machining, high efficiency machining, micro and nanomachining, among others. The formability and machinability of all materials will be considered, including metals, polymers, ceramics,composites,biomaterials,nanomaterials,specialmaterials,etc.Theseries covers the full range of tribological aspects such as surface integrity, friction and wear, lubrication and multiscale tribology including biomedical systems and manufacturing processes. It also covers modelling and optimization techniques applied in materials forming, machining and tribology. Contributions to this book series are welcome on all subjects of “green” materials forming, machining and tribology. To submit a proposal or request further information, please contact Dr. MayraCastro,PublishingEditorAppliedSciences,[email protected] or Professor J. Paulo Davim, Book Series Editor, via [email protected]. More information about this series at http://www.springer.com/series/11181 Sunil Pathak Gobinda C. Saha (cid:129) Editors Cold Spray in the Realm of Additive Manufacturing 123 Editors Sunil Pathak Gobinda C.Saha Faculty of Manufacturing NanocompositesandMechanicsLaboratory, andMechatronics Engineering Technology Department ofMechanical Engineering Universiti Malaysia Pahang University of NewBrunswick Kuantan,Pahang,Malaysia Fredericton, NB,Canada ISSN 2195-0911 ISSN 2195-092X (electronic) Materials Forming,Machining andTribology ISBN978-3-030-42755-9 ISBN978-3-030-42756-6 (eBook) https://doi.org/10.1007/978-3-030-42756-6 ©SpringerNatureSwitzerlandAG2020 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfrom therelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinor for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictionalclaimsinpublishedmapsandinstitutionalaffiliations. ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Preface Additivemanufacturingofengineeringpartsisessentialtofulfiltherequirementsof improved operating performance and longer service life. Manufacturing to the desired size, shape, surface quality and mechanical properties is possible with the help of precision additive manufacturing process such as “Cold Spray Additive Manufacturing” (CSAM). This book sheds light on the development of CSAM in the field of additive manufacturing and development of functional material prop- erties. This book covers the bonding mechanism, powder–substrate interface and salientfeaturesofCSAMtomanufacturenearnet-shapedparts.Thelatestresearch in this area and possible future research avenues are also highlighted to encourage further research and development in this field. This book consists of eight chapters on Cold Spray Additive Manufacturing (CSAM). Chapter “Cold Spray: Its Prominence as an Additive Manufacturing Technology”describesthefundamentalsofcoldsprayanddisplaysitsbenefitsover other competitive processes. Chapter “Commercial Cold Spray Equipment” sheds details on the development of commercial cold spray equipment. Chapter “The InfluenceofFeedstockPowder”providesacomprehensivereviewontheinfluence offeedstock powder in cold spray. Chapter “Cold Spray Deposition on Polymeric andCompositeSubstrates”shedslightoncapabilitiesofcoldsprayindepositionon polymeric and composite substrates. Advanced modelling and simulation of the cold spray process to resolve the additive manufacturing issues are discussed in Chapter“AdvancedModelingandSimulationToolstoAddressBuild-UpIssuesin Additive Manufacturing by Cold Spray”. Chapter “Laser Assisted Cold Spray Deposition”isfocusedonlaser-assistedcoldspraying.Hybridizationofcoldspray with laser remelting for development of shape memory alloys is discussed in Chapter “Development of CuAlNi Shape Memory Alloy Structures Using Cold Spray Deposition Technique with Laser Remelting”. Metrological aspects and dimensional aspects of cold spray additive manufacturingare presentedin Chapter “Dimensional Analysis and Laser-Ultrasonic Inspection of Cold Spray Additive Manufacturing Components”. v vi Preface We sincerely acknowledge Springer for this opportunity and their professional support. Finally, we would like to thank all the chapter contributors for their availability and valuable contributions. Kuantan, Malaysia Sunil Pathak Fredericton, NB, Canada Gobinda C. Saha December 2019 Contents Cold Spray: Its Prominence as an Additive Manufacturing Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Sunil Pathak and Gobinda C. Saha Commercial Cold Spray Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Julio Villafuerte The Influence of Feedstock Powder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Aleksandra Nastic, Daniel MacDonald, and Bertrand Jodoin Cold Spray Deposition on Polymeric and Composite Substrates . . . . . . 87 Antonello Astarita, Luca Boccarusso, Luigi Carrino, Massimo Durante, Alessia Serena Perna, and Antonio Viscusi Advanced Modeling and Simulation Tools to Address Build-Up Issues in Additive Manufacturing by Cold Spray . . . . . . . . . . 129 Michel Jeandin, Francesco Delloro, and Margaux Bunel Laser Assisted Cold Spray Deposition . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Venkata Satish Bhattiprolu and Luke N. Brewer Development of CuAlNi Shape Memory Alloy Structures Using Cold Spray Deposition Technique with Laser Remelting . . . . . . . . . . . . 197 S.Shiva,L.Michaux,A.Cockburn,D.Hopkinson,I.A.Palani,C.P.Paul, and W. O’. Neill Dimensional Analysis and Laser-Ultrasonic Inspection of Cold Spray Additive Manufacturing Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 219 C. V. Cojocaru, P. Vo, D. Levesque, C. Bescond, M. Rivard, J. Boisvert, G. Lamouche, M. Martin, and E. Irissou Index .... .... .... .... .... ..... .... .... .... .... .... ..... .... 245 vii About the Editors Dr. Sunil Pathak is specialized in gear engineering and advanced/hybrid manu- facturingprocesses.Hehasbeenworkinginthefieldofgearengineeringsincelast9 years and advanced manufacturing for over 6 years. He has conducted extensive research on advanced finishing of gears. He possesses specialized skills in gear finishing, gear metrology (micro, and macro-geometry) and measurement of gear accuracy. Presently he has been working on machining of difficult-to-machine materials using advanced machining processes such as EDM and WEDM. He is also working in developing cold spray coatings as sustainable process for manu- facturing of 3D additive manufacturing components and repair/remanufacturing engineering, where he has specially gained experience in materials and remanu- facturing engineering. He has developed analytical models of manufacturing pro- cessesandoptimizingparameterstoachieveoverallsustainabilityinmanufacturing. Dr. Gobinda C. Saha is an Associate Professor and Director of Nanocomposites and Mechanics Laboratory at theUniversity of New Brunswick, Canada. Inrecent past, Dr. Saha has led the R&D division at two successive nanocomposites man- ufacturing companies in conjunction with academic appointment at the University of Calgary, Canada. His focused research and innovation work in bio and nanos- tructured materials and additive manufacturing is dedicated to serve as bridge buildingbetweenindustryandacademia,onthedivulsionoftheoreticalknowledge into applied solutions. Pertaining work in nanostructured materials has contributed to design, synthesis, testing, and commercialization of two surface protective coating systems for oil and gas industry, developed on the high velocity oxy-fuel and cold spraying methodology. Simultaneously, Dr. Saha’s research in design, fabrication, processing, and characterization/testing of smart optical sensor rein- forced FRP composites and modelling has contributed to the dissemination of knowledgethroughpeer-reviewpublicationinover50researchpapers,twopatents, aswellasastrongsupervisionofgraduatethesisresearchtrackrecord.Dr.Sahahas given numerous invited talks on the topic of ‘Nanostructured Cermet Composites ix x AbouttheEditors and Biocomposites’. He has served as the Chair of ASME Composites & HeterogeneousMaterialsTechnicalCommittee,aswellthefoundingmemberofthe Joint Canada-USA Regulatory Cooperation Council on developing strategies for nanomaterials including risk assessment and management and uses of industrial nanomaterials.
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