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Modern Cold Spray Julio Villafuerte Editor Modern Cold Spray Materials, Process, and Applications 1 3 Editor Julio Villafuerte Corporate—Supersonic Spray Technologies CenterLine Windsor Ltd Windsor Ontario Canada ISBN 978-3-319-16771-8 ISBN 978-3-319-16772-5 (eBook) DOI 10.1007/978-3-319-16772-5 Library of Congress Control Number: 2015938600 Springer Cham Heidelberg New York Dordrecht London © Springer International Publishing Switzerland 2015 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part 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 or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. 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 authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. Printed on acid-free paper Springer International Publishing AG Switzerland is part of Springer Science+Business Media (www.springer.com) Preface Education, conceived as the sharing of knowledge between individuals and generations of individuals, represents a powerful tool by which human kind improves their understanding of the world around us towards, ideally at least, the creation of better societies where all individuals prosper, live happily, and in harmony with each other and their environments. Books are instruments of such principle, where the most current information can be perpetually stored to be shared among current and future generations of individuals. This book is intended for engineers, thermal spray applicators, manufacturing, business visionaries, and professionals who, through their innovative input, can make impact on the future of manufacturing. Over the years, there have been many different names for the technology, main focus of this book, many being better descriptors of its science and operating principles; however, the name “cold spray” appears to stick better than most; therefore, we have decided to refer to the technology accordingly. This book is about the evolution of the cold spray technology, the current state of the art, and its practical use. More than anything, cold spray is a solid-state material consolidation method; it is its ability of producing unique material consolidates in ways that are not attainable with other thermal methods, the main reason for its important place in modern manufacturing. Since its wide commercial inception at the beginning of the twenty-first century, there have been a number of excellent books written on the subject of cold spray. The persistent dynamic evolution of this technology requires that a continuous flow of renewed information becomes available to be shared among readers and individuals interested in the topic. This book contains cutting edge information on the cold spray technology at the time of its publication; however, without any promise that it includes absolutely all current developments and applications available in the marketplace. At the time of this publication, cold spraying was commercially used for dimen- sional restoration of difficult-to-repair materials, such as cast iron and magnesium alloys used in heavy equipment and noncritical aircraft components. The process was also reportedly being commercially used to create thermally and/or electrically conductive surfaces in nonconductive substrates. At the same time, similar to the nanotechnology buzzword of the 2000s, there was wide spread speculation on the v vi Preface potential benefit of using cold spray technology for additive manufacturing, another novel technique in which components could be fabricated by systematically con- solidating layers of materials, following a digital model. This book is comprised of 12 chapters written by well-known authors from the academic, research, and industrial world, who have already spent significant part of their professional careers on various aspects of the cold spray technology. Our hope is that, by reading this book, readers can get the inspiration necessary to further improve the process and nurture more real-world applications. I want to take this opportunity to sincerely thank all of the contributing authors for their valuable contributions; without these contributions this book would not be what it is supposed to be: a source of well-founded knowledge of cold spray technology for current and future generations. Their time and mental efforts to convey this information in written form is greatly appreciated. I also want to express my special thanks to CenterLine Windsor Ltd for providing me with a nurturing envi- ronment so that I could pursue this project. Sincere appreciation also goes to Ania Levinson and Abira Sengupta of Springer for their assistance with coordinating and final editing of the book. Their patience, especially when awaiting for long overdue drafts, is greatly appreciated. Last but not the least, I want to express my deep gratitude to my friends, Io- nel Botef, Vladimir Franjo, and Kofi Adomako for their emotional support during tough times in this phase of my life. To my girlfriend, Sandra, for her unconditional support during the production of this book. Her continuous encouragement helped me overcome my fears and frustrations. Finally, I want to dedicate this book to my three boys, Julian, Nico, Marcos, and their mother, Marcela, for what they represent in my life. Children are the future, who trespass our own mortality. I wish they can improve our society, whereby the good aspects of modern technology are fully ex- ploited more for the good of all than for the greed of a few. Windsor, On, Canada Julio Villafuerte February 2015 Contents 1 Overview ................................................................................................... 1 I. Botef and J. Villafuerte 2 The Physics of Cold Spray ...................................................................... 31 P. King, M. Yandouzi and B. Jodoin 3 Characteristics of Feedstock Materials .................................................. 73 T. Hussain, S. Yue and C.-J. LI 4 Coating Properties ................................................................................... 107 M. Jeandin, H. Koivuluoto and S. Vezzu 5 Residual Stresses and Fatigue Life Enhancement of Cold Spray ........ 225 H. Jahed and R. Ghelichi 6 Commercial Cold Spray Equipment and Automation ......................... 253 J. Villafuerte, W. Birtch and J. Wang 7 Laser-Assisted Cold Spray ...................................................................... 275 D. Christoulis and C. Sarafoglou 8 Quality Assurance .................................................................................... 303 L. Pouliot 9 Powder Reclamation Methods ................................................................ 317 J. Abelson vii viii Contents 10 Applications .............................................................................................. 341 V. K. Champagne, P.K. Koh, T. J. Eden, D. E. Wolfe, J. Villafuerte and D. Helfritch 11 Cold Spray Economics ............................................................................. 377 D. Helfritch, O. Stier and J. Villafuerte 12 Review on Cold Spray Process and Technology US Patents ................ 403 D. Goldbaum, D. Poirier, E. Irissou, J.-G. Legoux and C. Moreau Contributors J. Abelson Donaldson Company, Inc., Minneapolis, MN, USA W. Birtch Corporate—Supersonic Spray Technologies, CenterLine Windsor Ltd, Windsor, ON, Canada I. Botef School of Mechanical, Industrial, and Aeronautical Engineering, University of the Witwatersrand, Johannesburg, South Africa V. K. Champagne U.S. Army Reasearch Laboratory, Aberdeen Proving Ground, MD, USA D. Christoulis CeraMetal Surface Engineering S.A., Koropi, Greece T. J. Eden The Applied Research Laboratory, The Pennsylvania State University, Reston, VA, USA R. Ghelichi Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, MA, USA D. Goldbaum Automotive and Surface Transportation, National Research Council of Canada, Boucherville, QC, Canada D. Helfritch TKC Global, Hearndon, VA, USA T Hussain Division of Materials, Mechanics and Structure, Faculty of Engineering, University of Nottingham, Nottingham, UK E. Irissou Automotive and Surface Transportation, National Research Council of Canada, Boucherville, QC, Canada H. Jahed Mechanical and Mechatronics Engineering Department, University of Waterloo, Waterloo, ON, Canada M. Jeandin MINES ParisTech, Paris, France B. Jodoin University of Ottawa, Ottawa, ON, Canada ix x Contributors P. King CSIRO, Clayton, VIC, Australia P.K. Koh SIM University, Singapore, Singapore H. Koivuluoto University of Tampere, Tampere, Finland J.-G. Legoux Automotive and Surface Transportation, National Research Council of Canada, Boucherville, QC, Canada C.-J. Li School of Materials Science & Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi, PRC C. Moreau Department of Mechanical and Industrial Engineering, Concordia University, Montreal, QC, Canada D. Poirier Automotive and Surface Transportation, National Research Council of Canada, Boucherville, QC, Canada L. Pouliot Tecnar Automation Ltd., St-Bruno, QC, Canada C. Sarafoglou School of Naval Architecture and Marine Engineering, National Technical University of Athens, Athens, Greece O. Stier Corporate Technology, Siemens AG, Berlin, Germany S. Vezzu Veneto Nanotech, Venezia, Italy J. Villafuerte Corporate—Supersonic Spray Technologies, CenterLine Windsor Ltd, Windsor, ON, Canada J. Wang Corporate—Supersonic Spray Technologies, CenterLine Windsor Ltd, Windsor, ON, Canada D. E. Wolfe The Applied Research Laboratory, The Pennsylvania State University, Reston, VA, USA M. Yandouzi University of Ottawa, Ottawa, ON, Canada S Yue Department of Mining and Materials Engineering, McGill University, Montreal, QC, Canada