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High Rate Deposition in Cold Spray

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Abstract

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.

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Acknowledgments

This work was sponsored in part by the U.S. Army Research Laboratories under the Grant Number W911NF-15-2-0026. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the U.S. Government. The authors would like to thank Baillie Haddad and VRC Metal Systems for allowing the use of their microhardness equipment (Webster, MA, USA). The authors would also like to thank Lauren Randaccio and Joel Sanchez (Northeastern University, Boston, MA, USA) for assisting the cold spray experiments, Robert Allegretto (VRC Metal Systems, Rapid City, SD) in thermal conductivity sample preparation, and William Carpenter (South Dakota School of Mines and Technology, Rapid City, SD,) for EBSD sample preparation.

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, Northeastern University, Boston, MA, USA

    Ozan C. Ozdemir, Patricia Schwartz & Sinan Muftu

  2. Arbegast Materials Processing & Joining Laboratory, South Dakota School of Mines & Technology, Rapid City, SD, USA

    Forest C. Thompson & Grant A. Crawford

  3. Army Research Laboratory, Aberdeen Proving Ground, Aberdeen, MD, USA

    Aaron T. Nardi & Victor K. Champagne Jr.

  4. VRC Metal Systems, Rapid City, SD, USA

    Christian A. Widener

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  1. Ozan C. Ozdemir
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Correspondence to Ozan C. Ozdemir.

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Production Notes: ITSC credit line: This article is an invited paper selected from presentations at the 2019 International Thermal Spray Conference, held May 26–29, 2019 in Yokohama, Japan and has been expanded from the original presentation.

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Ozdemir, O.C., Schwartz, P., Muftu, S. et al. High Rate Deposition in Cold Spray. J Therm Spray Tech 30, 344–357 (2021). https://doi.org/10.1007/s11666-020-01135-1

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