Cold spray is a green additive manufacturing method that accelerates micron-size particles to supersonic speeds. At these high speeds, the particles deposit upon impact with a desired surface. High-density polyethylene, polyurethane, polyamide-12, polystyrene, and ultra-high molecular weight polyethylene particles were cold-sprayed onto a low-density polyethylene substrate under different process conditions. Glass beads with diameters between 20 and 120 µm were added to each batch to study the effect of non-adhesive peening particles on the deposition efficiency and the quality of the final deposited layer of a series different polymeric powders. The successful deposition window was compared for the cold spray process with and without the addition of glass beads. Adding the glass beads to the polymer powders was found to widen the successful windows of deposition to both higher and lower impact velocities at a given temperature for all the polymer powder studied. In addition, adding peening particles were found to make deposition possible at lower particle temperatures where deposition had not been successful previously. This was especially important for ultra-high molecular weight polyethylene particles for which deposition in the absence of peening particles was not possible below 60 °C, but with peening particles was successful even at room temperature. Peening particles were found to increase deposition efficiency by as much as 50% for a given set of deposition conditions. The appropriate size of the added glass beads to maximize the deposition efficiency was found to be comparable to the size of the depositing particles. The addition of glass beads was also found to reduce the surface roughness of the deposited layer by more than 50%. Finally, for processing conditions with particle velocities below a Mach number of one, no glass beads were found to adhere to the resulting cold-sprayed substrates.

中文翻译：

---

玻璃珠在聚合物粉末冷喷涂沉积中的喷丸效果

冷喷涂是一种绿色增材制造方法，可将微米级颗粒加速至超音速。在这些高速下，颗粒在与所需表面碰撞时沉积。在不同的工艺条件下，将高密度聚乙烯、聚氨酯、聚酰胺 12、聚苯乙烯和超高分子量聚乙烯颗粒冷喷涂到低密度聚乙烯基材上。将直径在 20 到 120 µm 之间的玻璃珠添加到每批中，以研究非粘性喷丸颗粒对沉积效率和一系列不同聚合物粉末最终沉积层质量的影响。比较冷喷涂工艺中添加和不添加玻璃珠的成功沉积窗口。发现将玻璃珠添加到聚合物粉末中可以将所有研究的聚合物粉末在给定温度下的成功沉积窗口扩大到更高和更低的冲击速度。此外，发现添加喷丸颗粒可以在较低的颗粒温度下进行沉积，而此前沉积并不成功。这对于超高分子量聚乙烯颗粒尤其重要，因为在低于 60 °C 的情况下不可能在没有喷丸颗粒的情况下沉积，但即使在室温下喷丸颗粒也能成功沉积。发现对于给定的一组沉积条件，喷丸颗粒可将沉积效率提高多达 50%。发现添加玻璃珠的合适尺寸以最大化沉积效率与沉积颗粒的尺寸相当。还发现添加玻璃珠可将沉积层的表面粗糙度降低 50% 以上。最后，对于粒子速度低于马赫数 1 的加工条件，没有发现玻璃珠粘附到所得冷喷涂基材上。