Journal ArticleDOI
Evaluation of residual stresses induced by cold spraying of Ti-6Al-4V on Ti-6Al-4V substrates
Dibakor Boruah,Bilal Ahmad,Tung Lik Lee,Saurabh Kabra,Abdul Khadar Syed,Philip McNutt,Matthew Doré,Xiang Zhang +7 more
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In this paper, the effects of geometrical variables (i.e., the number of CS layers, CS layer thickness, and substrate thickness) and track pattern on the magnitude and distribution of residual stresses in CS deposit-substrate assemblies were measured experimentally by neutron diffraction and contour method.Abstract:
Cold spray (CS) is a solid-state additive material deposition technique, which has gained attention in the aerospace industry as a potentially viable technology for structural repair of high-value parts made of high-strength alloys such as Ti-6Al-4V (Ti-64). Residual stresses build up in the substrate and deposited materials resulting from the CS process can influence the integrity of a coating or repair. However, the nature, magnitude and distribution of residual stresses in Ti-64/Ti-64 CS repairs are currently unknown. This study aims to evaluate the effects of geometrical variables (i.e. the number of CS layers, CS layer thickness, and substrate thickness) and track pattern on the magnitude and distribution of residual stresses in CS deposit-substrate assemblies. Through-thickness stress distributions were measured experimentally by neutron diffraction and contour method. Furthermore, a comparison among different residual stress build-up mechanisms induced by CS processes has been discussed for different combinations of substrate and deposit assemblies. An analytical model based on the force and moment equilibrium requirements was used to interpret the experimental stress profiles and to predict the residual stress distribution. It was found that residual stresses are highly tensile near the free surface of the Ti-64 deposits as well as towards the bottom of the substrate, and compressive near the interface region. Although all the specimens showed similar stress distribution, the magnitudes were found to be higher in one or more of the following cases: specimens with a higher number of CS layers, lower substrate thickness, higher layer thickness (i.e. at lower scanning speed), and deposited with a horizontal track pattern.read more
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Solid-state cold spraying of Ti and its alloys: A literature review
Wenya Li,Congcong Cao,Shuo Yin +2 more
TL;DR: In this paper, a review of the deposition characteristics of Ti and its alloys during cold spraying is presented, in an effort to shed light on them and expand their applications and further applications, such as protective coatings, biocompatible coatings and additive manufacturing.
Journal ArticleDOI
A comprehensive review on sustainable cold spray additive manufacturing: State of the art, challenges and future challenges
Gaurav Prashar,Hitesh Vasudev +1 more
TL;DR: In this paper, a review sums up the research on state-of-the-art and identified key challenges for deploying a CSAM as a repairing, restoration and sustainable fabrication process in the future manufacturing industry.
Journal ArticleDOI
Numerical modelling of particle impact and residual stresses in cold sprayed coatings: A review
TL;DR: In this article, a review of the experimental techniques used for residual stress measurements; such as X-ray diffraction, neutron diffraction and material removal, curvature measurement and deformation techniques, are concisely reviewed from the context of being applied to cold spray deposits.
Journal ArticleDOI
Post-process treatments on supersonic cold sprayed coatings : a review
TL;DR: In this article, the effects of different post-process treatments on the microstructure, residual stress and mechanical properties of cold sprayed deposits are discussed, including heat treatment, friction-stir processing, shot peening, and laser re-melting.
Journal ArticleDOI
Cold spray additive manufacturing of Invar 36 alloy: microstructure, thermal expansion and mechanical properties
Chaoyue Chen,Y.J. Xie,Longtao Liu,Ruixin Zhao,Xiaoli Jin,Shanqing Li,Renzhong Huang,Jiang Wang,Hanlin Liao,Zhongming Ren +9 more
TL;DR: In this article, the Invar 36 alloys were manufactured using cold spray (CS) additive manufacturing technique, and a systematic investigation was made on the microstructural evolution, thermal expansion and mechanical properties under as-sprayed (AS) and heat-treated (HT) conditions.
References
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TL;DR: Titanium and titanium alloys are excellent candidates for aerospace applications owing to their high strength to weight ratio and excellent corrosion resistance as discussed by the authors.However, titanium usage is strongly limited by its higher cost relative to competing materials, primarily aluminum alloys and steels.
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Journal ArticleDOI
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Peter Mercelis,Jean-Pierre Kruth +1 more
TL;DR: In this paper, a simple theoretical model is developed to predict residual stress distributions in selective laser sintering (SLS) and selective laser melting (SLM), aiming at a better understanding of this phenomenon.
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Cross-sectional mapping of residual stresses by measuring the surface contour after a cut
TL;DR: In this paper, a part is cut in two, and the contour, or profile, of the resulting new surface is measured to determine the displacements caused by release of the residual stresses.
Journal ArticleDOI
Cold spraying - A materials perspective
TL;DR: In this article, the authors provide an overview of the cold spray process, the current understanding of the deposition mechanisms, and the related models and experiments, from a materials science perspective.