Industrialization of cold spray introduces concerns regarding the cost and time efficiency of cold spray procedures. In this work, high rate deposition of tantalum was studied computationally and experimentally. Quasi-1D multiphase fluid simulations predicted minimal effects on the bonding conditions of particles with 5% to 14% increase in powder-to-gas mass flow ratio. Experimental specimens were produced to observe the mechanical and microstructural effects of increased powder stream loading. Adhesion and hardness tests as well as thermal conductivity, optical microscopy, and electron backscatter diffraction examinations only exhibited minor differences in the mechanical and microstructural properties of the specimens. The increased powder stream loading rate, however, allows a significant reduction in the time required for depositing the same amount of tantalum by a factor of three. The results of the study enable shorter cold spray deposition time. This leads to significant cost savings associated with consumption of helium and labor, while facilitating shorter turn-around times for repairing components and manufacturing of cold-sprayed products.

中文翻译：

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冷喷涂中的高速沉积

冷喷涂的工业化带来了对冷喷涂程序的成本和时间效率的担忧。在这项工作中，通过计算和实验研究了钽的高速沉积。准一维多相流体模拟预测，粉末与气体质量流量比增加 5% 至 14% 时，对颗粒结合条件的影响最小。制作实验样品以观察增加粉末流负载的机械和微观结构影响。附着力和硬度测试以及热导率、光学显微镜和电子背散射衍射检查仅显示试样的机械和显微结构特性的微小差异。然而，增加的粉末流加载速率，允许将沉积相同数量的钽所需的时间显着减少三倍。研究结果可以缩短冷喷涂沉积时间。这会显着节省与氦气和劳动力消耗相关的成本，同时有助于缩短维修部件和制造冷喷涂产品的周转时间。