journal article·2017-08-14Open access

Development of Sustainable Cold Spray Coatings and 3D Additive Manufacturing Components for Repair/Manufacturing Applications: A Critical Review

Sunil Pathak, Gobinda Saha

Coatings· Volume 7· Issue 8

Abstract

This review article presents the findings of a comprehensive state-of-the-art literature review of the scientific and technological progress of the cold spray process in the field of repair/remanufacturing using the concept of additive manufacturing. A thorough study was conducted on the potential of this technology to form (a) both thin and thick coatings; (b) the ability to fabricate 3D freeform components in a single process, while benefiting from reduced residual stress level compared to conventional thermal spray coatings processes such as high velocity oxy-fuel (HVOF) or plasma spraying. A systematic overview of the process technology, particularly focusing on the suitability of ceramic-metallic (cermet) composite particles used as feedstock in the deposition was conducted; further elaboration was made pertinent to particle impact and bonding mechanisms during the deposition.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: High-Temperature Coating Behaviors · Advanced materials and composites · Advanced ceramic materials synthesis

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Faculty of Engineering Technology, University Malaysia Pahang, Pahang 26300, Malaysia

Department of Mechanical Engineering, University of New Brunswick, Fredericton, NB E3B 5A3, Canada

References (72)

Show source-provided references
1. Optimization and characterization of high velocity oxy-fuel sprayed coatings: Techniques, materials, and applications10.3390/coatings1010017 ↗
2. Knowledge concerning splat formation: An invited review10.1361/10599630419670 ↗
3. Tribological behavior of nanostructured HVOF thermal sprayed WC-17NiCr coatings10.1016/j.ceramint.2016.10.193 ↗
4. Mechanical property changes in HVOF sprayed nanostructured WC-17wt %Ni(80/20)Cr coating with varying substrate roughness
5. Tribological behavior of HVOF sprayed near-nanostructured and microstructured WC-17 wt %Co coatings10.1016/j.surfcoat.2011.07.075 ↗
6. Erosion-corrosion resistance of microcrystalline and near-nanocrystalline WC-17Co high velocity oxy-fuel thermal spray coatings10.1016/j.corsci.2011.02.028 ↗
7. Comparative abrasive wear study of HVOF coatings obtained by spraying WC-17Co microcrystalline and duplex near-nanocrystalline cermet powders10.1115/1.4004689 ↗
8. The corrosion and wear performance of microcrystalline WC-10Co-4Cr and near-nanocrystalline WC-17Co HVOF sprayed coatings on steel substrate10.1007/s11661-010-0296-1 ↗
9. Nanostructured composite coatings for oil sands applications10.1179/174329409X439050 ↗
10. Development of wear resistant nanostructured duplex coatings by HVOF process for use in oil sands industry10.1166/jnn.2009.M52 ↗
11. Davis, J.R. (2004). Handbook of Thermal Spray Technology, ASM International.
12. Knight, R., and Smith, R.W. (1998). Thermal Spray Forming Materials, Powder Metal Technologies and Applications, ASM International. ASM Handbook.
13. Hermanek, F.J. (2001). Thermal Spray Terminology and Company Origins, ASM International. [1st ed.].
14. From powders to thermally sprayed coatings10.1007/s11666-009-9435-x ↗
15. Oxidation of stainless steel in the high velocity oxy fuel process10.1361/105996300770349872 ↗
16. Thermal Spray: Industry in Transition
17. Ludema, K.C. (1996). Friction, Wear, Lubrication: A Textbook in Tribology, CRC Press.10.1201/9781439821893 ↗
18. Davis, J.R. (2001). Surface Engineering for Corrosion and Wear Resistance, ASM International.10.31399/asm.tb.secwr.9781627083157 ↗
19. Method of cold gas-dynamic deposition
20. Review on cold spray process and technology: Part-I-intellectual property10.1007/s11666-008-9203-3 ↗
21. Cold spray coating: Review of materials systems and future perspectives10.1179/1743294414Y.0000000270 ↗
22. Tucker, R.C. (1994). Thermal Spray Coating: Surface Engineering, ASM International. ASM Handbook.
23. Cold spray technology
24. Champagne, V.K. (2007). The Cold Spray Materials Deposition Process: Fundamentals and Applications, Woodhead.10.1201/9781439824122 ↗
25. New developments in cold spray based on higher gas and particle temperatures10.1361/105996306X147144 ↗
26. Rokni, M.R., Nutt, S.R., Widener, C.A., Champagne, V.K., and Hrabe, R.H. (2017). Review of relationship between particle deformation, coating microstructure, and properties in high-pressure cold spray. J. Therm. Spray Technol., 1–48.10.1007/s11666-017-0575-0 ↗
27. The 2016 thermal spray roadmap10.1007/s11666-016-0473-x ↗
28. Cold spraying—A materials perspective10.1016/j.actamat.2016.06.034 ↗
29. Adiabatic shear instability based mechanism for particles/substrate bonding in the cold-gas dynamic-spray process10.1016/j.matdes.2004.03.008 ↗
30. Bonding mechanism in cold gas spraying10.1016/S1359-6454(03)00274-X ↗
31. Interface material mixing formed by the deposition of copper on aluminium by means of the cold spray process10.1361/105996305X59332 ↗
32. Computational analysis of the interfacial bonding between feed-powder particles and the substrate in the cold-gas dynamic-spray process10.1016/S0169-4332(03)00643-3 ↗
33. Theoretical and experimental particle velocity in cold spray10.1007/s11666-010-9530-z ↗
34. Numerical study of combination parameters for particle impact velocity and temperature in cold spray10.1007/s11666-007-9087-7 ↗
35. From particle acceleration to impact and bonding in cold spraying10.1007/s11666-009-9357-7 ↗
36. Numerical study of in-flight particle parameters in low-pressure cold spray process10.1007/s11666-010-9548-2 ↗
37. Modelling aspects of high velocity impact of particles in cold spraying by explicit finite element analysis10.1007/s11666-009-9325-2 ↗
38. Modelling of impact behaviour of cold spray particles: Review10.1179/1743294414Y.0000000268 ↗
39. Stoltenhoff, T., Kreye, H., Kroemmer, W., and Richter, H.J. (2000, January 16–17). Cold Spraying—From Thermal Spraying to High Kinetic Energy Spraying. Proceedings of the 5th HVOF Colloquium, Erding, Germany.
40. Papyrin, A.N., Klinkov, S.V., and Kosarev, V.F. Effect of the substrate surface activation on the process of cold spray coating formation. Thermal Spray Connects: Explore Its Surfacing Potential, Proceedings of the Thermal Spray Conference, Basel, Switzerland, 2–4 May 2005.10.31399/asm.cp.itsc2005p0145 ↗
41. Cold gas dynamic spraying of a high temperature Al alloy10.1016/j.surfcoat.2005.06.001 ↗
42. Effect of powder feed rate on the mechanical properties of WC-5 wt %Ni coatings deposited using low pressure cold spray10.1016/j.ijrmhm.2016.10.001 ↗
43. Characterization and modeling of the bonding process in cold spray additive manufacturing
44. Brendt, C.C., Khor, K.A., and Lugscheider, E. (2001). Effects of shock waves on impact velocity of cold spray particles. Thermal Spray 2001: New Surfaces for a New Millennium, ASM International.
45. Effect of particle size, morphology, and hardness on cold gas dynamic sprayed aluminum alloy coatings10.1016/j.surfcoat.2006.07.232 ↗
46. Marple, B.R., and Moreau, C. (2003). Effect of Spray Angle on Deposition Characteristics in Cold Spraying. Thermal Spray 2003: Advancing the Science and Applying the Technology, ASM International.
47. The influence of Al2O3 particle morphology on the coating formation and dry sliding wear behavior of cold sprayed Al-Al2O3 composites10.1016/j.surfcoat.2015.01.057 ↗
48. Investigation and characterization of Stellite-based wear-resistant coatings applied to steel moulds by cold-spray10.1016/j.cirp.2015.04.031 ↗
49. Cold-spray processing of a high density nanocrystalline aluminum alloy 2009 coating using a mixture of as-atomized and as-cryomilled powders10.1007/s11666-011-9652-y ↗
50. Experimental study of titanium/aluminium deposits produced by cold gas dynamic spray10.1016/j.surfcoat.2004.10.133 ↗
51. Rapidly solidified Zn-Al powder on surface of Mg alloy by cold spray method
52. Microstructure and nano-mechanical property of cold spray Co-base refractory alloy coating
53. Coating deposition by the kinetic spray process10.1016/j.surfcoat.2005.04.033 ↗
54. Fabrication of aluminum–alumina metal matrix composites via cold gas dynamic spraying at low pressure followed by friction stir processing10.1016/j.msea.2012.06.066 ↗
55. Tungsten/copper composite deposits produced by a cold spray10.1016/j.scriptamat.2003.08.023 ↗
56. Low temperature deposition and characterization of TiO2 photocatalytic film through cold spray10.1016/j.apsusc.2007.12.016 ↗
57. Synthesis and characterization of nanocrystalline Al2O3-Ni(Cr) particles using high-energy mechanical alloying process10.1016/j.surfcoat.2017.01.024 ↗
58. The use of particle/substrate material models in simulation of cold-gas dynamic-spray process10.1007/s11666-013-0051-4 ↗
59. Fabrication of titanium dioxide photocatalyst coatings by cold spray10.1299/jmmp.3.210 ↗
60. Net shape fins for compact heat exchanger produced by cold spray10.1007/s11666-013-9968-x ↗
61. Nardi, A. (2013, January 11–13). Advanced manufacturing—The 21st century materials design space. Presented at Workshop on Future Research Needs in Advanced Manufacturing from Industrial Perspective, Arlington, VA, USA.
62. (2017, August 01). Moog Brochure: Cold Spray Surface Repair. Available online: http://www.midamericaaviation.com/products-services/cold-spray-surface-repair/.
63. Malison, E. (2013, January 13). Practical Application of SST™ Equipment, Powders and Knowledge. Presented at 2013 CSAT Workshop, Worchester, MA, USA.
64. (2017, August 01). General Electric Product Brochure. Available online: http://www.geaviation.com/company/additive-manufacturing.html.
65. A novel spiral trajectory for damage component recovery with cold spray10.1016/j.surfcoat.2016.10.096 ↗
66. King, P., Vucko, M., Poole, A., Jahedi, M., and de Nys, R. (2017, August 01). Cold Spray Antifouling of Marine Seismic Streamers. Available online: https://publications.csiro.au/rpr/download?pid=csiro:EP124574&dsid=DS1.
67. A demonstration of the antimicrobial effectiveness of various copper surfaces10.1186/1754-1611-7-8 ↗
68. Cold spray metal embedment: An innovative antifouling technology10.1080/08927014.2012.670849 ↗
69. A review on tailored blanks: Production, applications and evaluation10.1016/j.jmatprotec.2013.08.015 ↗
70. Ashrafizadeh, H., Lopera-Valle, A., McDonald, A., and Gerlich, A. (2015, January 11–14). Effect of Friction-stir processing on the wear rate of WC-based MMC coatings deposited by low pressure cold gas dynamic spraying. Proceedings of the International Thermal Spray Conference (Thermal Spray 2015), Long Beach, FL, USA.10.31399/asm.cp.itsc2015p0041 ↗
71. Cold spraying: From process fundamentals towards advanced applications10.1016/j.surfcoat.2014.09.060 ↗
72. The erosion performance of cold spray deposited metal matrix composite coatings with subsequent friction stir processing10.1016/j.apsusc.2016.10.156 ↗