| WU Yingdong,LU Jing,SUN Chengchuan,CHEN Zibin,XIE Hui.Progress of the Additive Manufacturing Applications of Cold Spray Technique[J],53(16):19-34, 67 |
| Progress of the Additive Manufacturing Applications of Cold Spray Technique |
| Received:October 31, 2023 Revised:December 24, 2023 |
| View Full Text View/Add Comment Download reader |
| DOI：10.16490/j.cnki.issn.1001-3660.2024.16.002 |
| KeyWord:cold spray additive manufacturing metal manufacturing efficiency forming quality spray strategy |
| Author | Institution |
| WU Yingdong |
Jihua Laboratory, Guangdong Foshan , China;College of Mechanical and Vehicle Engineering, Hunan University, Changsha , China |
| LU Jing |
Jihua Laboratory, Guangdong Foshan , China |
| SUN Chengchuan |
Jihua Laboratory, Guangdong Foshan , China |
| CHEN Zibin |
Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong , China |
| XIE Hui |
Jihua Laboratory, Guangdong Foshan , China;College of Mechanical and Vehicle Engineering, Hunan University, Changsha , China |
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| Abstract: |
| Cold spray additive manufacturing (CSAM) is an emerging rapid additive manufacturing method that distinguishes itself from conventional metal additive manufacturing methods. In CSAM, the temperature during the process remains below the melting point of the material, which minimizes the impact of heat on the metal material, thereby mitigating issues such as oxidation, phase change or crystallization. Due to its distinctive process characteristics, such as the solid-state deposition and the utilization of aerodynamic power as a manufacturing power source, as well as its advantages in terms of high efficiency in additive manufacturing and the ability to create unlimited forming sizes, CSAM has emerged as a prominent focus of interest in the field. The work aims to explore the advantages of CSAM, determine its application orientation and analyze its defects, in order to study improvement methods. Several typical metal additive manufacturing methods, including selective laser melting (SLM), selective electron beam melting (SEBM), wire arc additive manufacturing (WAAM), laser metal direct forming (LMDF), friction stir additive manufacturing (FSAM), and CSAM, were analyzed and compared. The analysis focused on manufacturing efficiency, production cost, forming size, forming precision, product mechanical properties, and process materials. The comparison results indicated that the CSAM demonstrated superior additive efficiency and lower manufacturing cost per unit volume compared to other methods. Additionally, CSAM was applicable to a wider range of materials, thereby enhancing its technological competitiveness in the field of additive manufacturing. However, the forming mechanism of CSAM presented certain challenges, including inadequate forming accuracy and subpar mechanical properties of the products. Therefore, it remained essential to employ appropriate strengthening processes and traditional subtractive manufacturing methods to provide assistance. With the aim of improving the forming quality and enhancing the forming ability of CSAM in complex structures, the recent advancements in the optimization of the CSAM process, the improvement of spraying nozzles, and the innovation of spraying strategies were discussed. The analysis focused on examining the correlation between various parameters of the spray process and both the performance of the spray technique and the quality of the deposition. Additionally, the investigation involved the utilization of miniaturized nozzles to enhance the precision of spraying during the forming process. Furthermore, more systematic forming strategies were employed to enhance the forming capability of CSAM in intricate geometries. At present, numerous scientific institutions and technology companies have demonstrated the viability of CSAM, the current applications of CSAM in rotary additive forming, free additive forming, damage repair, and structural remanufacturing. Furthermore, the crucial role of CSAM in specific applications was analyzed and the potential future application scenarios for CSAM were explored. Following this, the present challenges and potential avenues for development in CSAM were presented, with a particular emphasis on its application value and objectives in the context of rapid additive manufacturing. Currently, there is a growing interest in exploring different additive processes to overcome the limitations of existing additive manufacturing methods and unlock their full potential. Compared to alternative techniques, cold spray has emerged as a highly promising approach for metal additive manufacturing, primarily due to its exceptional additive efficiency and low-temperature processing capabilities. However, there are still certain deficiencies in forming accuracy and mechanical characteristics. In the foreseeable future, once the pertinent issues are resolved, the industrial implementation of CSAM is poised to be achieved. |
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