The Cold Spray Materials Deposition Process: Fundamentals and Applications

This pioneering book reviews both the fundamentals of the process and how it can best be applied in practice. The first part of the book discusses the development of the process together with its advantages and disadvantages in comparison with thermal spray coating techniques. Part 2 reviews key process parameters such as powders, nozzle design, particle temperature and velocity, and particle/substrate interaction. It also describes portable and stationary cold spray systems. The final part of the book discusses how the cold spray process can be applied in such areas as improved wear, corrosion protection, electromagnetic interference shielding and repair of damaged components.

Table of Contents:
INTRODUCTION V K Champagne, US Army Research Laboratory, USA PART 1 GENERAL ISSUES The Development of the Cold Spray Process A Papyrin, Cold Spray Technology (CST), USA - History of cold spray - Discovery of the cold spray phenomenon and its basic features - Initial studies on development of cold spray - Basic physical principles and key features - Evolution of cold spray technology and current status - Some comments on the patent situation - Symbol list - References Comparing cold spray with thermal spray coating technologies M F Smith, Sandia National Laboratories, USA - Introduction - Traditional thermal spray technologies - Comparison of cold spray to traditional thermal spray - Conclusions - References The advantages and disadvantages of the cold spray coating process J Karthikeyan, ABS Industries Inc, USA - Introduction - Advantages of the cold spray process - Disadvantages of the cold spray process - References The economics of the cold spray process S Celotto, J Pattison, J S Ho, A N Johnson and W O’Neill, Innovative Manufacturing Research Centre, UK - Introduction - Cold spray equipment and infrastructure - Consumables - Comparison to other thermal spray techniques - Comparison to other additive fabrication techniques - Conclusions and future trends - Sources of further information and advice - References PART 2 COLD SPRAY PROCESS PARAMETERS Cold spray process parameters: powders F J Brodmann, F J Brodmann & Co, USA - Introduction - Selection criteria for cold spray feedstock - Key powder properties - Powder manufacturing process - New material developments - Discussion - Conclusions - Acknowledgements - References The influence of nozzle design in the cold spray process K Sakaki, Shinshu University, Japan - Introduction - Numerical simulation of cold spray process - Nozzle design influences - References The role of particle temperature and velocity in cold spray coating formation T Van Steenkiste, Delphi Systems, USA - Introduction - Particle velocity and temperature - The impact of particle velocity and temperature on coating formation - Altering particle temperature - Conclusions - Acknowledgements - References Particle/substrate interaction in the cold spray bonding process M Grujicic, Clemson University, USA - Introduction - Transient non-linear dynamics analysis of the cold-gas particle/substrate interactions - Adiabatic shear instability and plastic-flow localization - The role of interfacial instability - Conclusions - References Supersonic jet/substrate interaction in the cold spray bonding process V F Kosarev, S V Klinkov and A Papyrin, A Papyrin, Cold Spray Technology (CST), USA - Introduction - Investigation of supersonic air jet exhausting from a nozzle - Impact of a supersonic jet on a substrate - Heat transfer between a supersonic plane jet and a substrate under conditions of cold spray - Symbol list - References Portable, low pressure cold spray systems for industrial applications R Maev, V Leshchynsky and E Strumban, University of Windsor, Canada - State-of-art cold spray systems - State-of-art powder feeding systems - Modification of the low pressure portable GDS system - Industrial low pressure portable GDS system - References Stationary cold spray systems for industrial applications H Höll, Cold Spray Technology GmbH, Germany - Introduction - Industrial cold gas spray equipment: system layout, gas supply and control cabinet - Industrial cold spray equipment: gas heater, powder feeder and cold spray gas - References PART 3 APPLICATIONS OF COLD SPRAY COATINGS Mechanical, thermal and electrical properties of cold sprayed coatings A Gouldstone, W B Choi, W Chi, Y Wu and S Sampath, State University of New York at Stony Brook, USA - Introduction - Materials used for analysis - Mechanical property measurements - Microstructural characterization of coatings - Properties of coatings - Comparison of cold-spray coatings with traditional thermal spray of coatings - Conclusions - Acknowledgements - References Cold spray particle deposition for improved wear D Wolfe and T Eden, Penn State University, USA - Introduction - Current state of the art - Cold spray wear resistant material properties - Cold spray wear resistant processing - Characterization - Powder characteristics - X-ray diffraction (XRD) and phase analysis - Scanning electron microscopy - Tribology - Adhesion and bond strength - Potential hybrid process combining cold spray can laser processing - Conclusions The use of cold spray coating for corrosion protection R C McCune, formerly Ford Motor Company, USA - Introduction - Cold spraying of metals as a coatings technology for corrosion control - Galvanising of steel structures to prevent corrosion - Preventing aqueous and hot-surface corrosion - Conclusions - References Electromagnetic interference shielding by cold spray particle deposition D J Helfritch, US Army Research Laboratory, USA - Introduction - Cold spray particle deposition - Parameter screening - Screening tests - Application - Conclusions - Acknowledgements - References Repair of magnesium components by cold spray techniques V K Champagne, US Army Research Laboratory, USA - Introduction - Problems in using magnesium components - Limitations of current technologies - Key issues in using the cold spray process - Developing and testing cold spray coating of magnesium - Cold spray technology for coating magnesium - Predictive modelling process optimization - Cold spray trials - Coating characterization - Cost savings and implementation - Conclusions - References

About the Author :
US Army Research Laboratory, USA