Abstract
In cold spray additive manufacturing (CSAM), the severe plastic deformation of the input powder particles leads to an accumulation of residual stresses, the magnitude of which is affected by process conditions. In the current study, the effects of traverse speed and powder feed rate on the residual stress state were investigated in commercially pure titanium cylinders produced by CSAM. Residual stress measurements were made in a grid pattern covering the 2D cross section using the KOWARI neutron diffractometer at ANSTO, Australia, and selected results were validated using the contour method. It was found that the thermal effect was dominant on the residual stress state generating a tensile state near the inner and outer surfaces of the cylinder walls while compressive residual stresses tend to accumulate in the center of the wall. The residual stresses were dominated by thermal stresses at low traverse speed, while peening becomes more critical at high traverse speeds. Increasing the powder feed rate increased the magnitude of the residual stresses. High traverse speeds and low feed rates are beneficial for producing 3D parts by CSAM. However, slow traverse speeds are more detrimental than high feed rates for a given layer thickness.
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Acknowledgments
Access to the neutron strain scanner (KOWARI) at the Australian Nuclear Science and Technology Organisation (ANSTO) was provided through proposal P6886. Thanks are due to Tim Palmer, ANSTO, and Emma Regos, CSIRO, for sample preparation and polishing, and Ken Short, ANSTO, for his assistance in performing the nano-indentation experiments; Tim Nicholls, ANSTO, for his assistance in instrumenting the sample for the contour method; and the ANSTO workshop for the construction of the constraint jig. The authors are also grateful to Christian Busch formally of Helmut Schmidt University, Germany, and Andrew Urban, CSIRO, for their assistance with cold spray temperature measurements. The authors would like to acknowledge the financial support provided by the CSIRO and its Active Integrated Matter Future Science Platform (AIM FSP).
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This article is part of a special topical focus in the Journal of Thermal Spray Technology on Advanced Residual Stress Analysis in Thermal Spray and Cold Spray Processes. This issue was organized by Dr. Vladimir Luzin, Australian Centre for Neutron Scattering; Dr. Seiji Kuroda, National Institute of Materials Science; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang, Swinburne University of Technology.
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Vargas-Uscategui, A., King, P.C., Styles, M.J. et al. Residual Stresses in Cold Spray Additively Manufactured Hollow Titanium Cylinders. J Therm Spray Tech 29, 1508–1524 (2020). https://doi.org/10.1007/s11666-020-01028-3
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DOI: https://doi.org/10.1007/s11666-020-01028-3