J. Mater. Sci. Technol. ›› 2018, Vol. 34 ›› Issue (3): 440-457.DOI: 10.1016/j.jmst.2017.09.015
Special Issue: 增材制造/3D打印专辑
• Orginal Article • Previous Articles Next Articles
Wenya Lia*(), Kang Yanga, Shuo Yinb, Xiawei Yanga, Yaxin Xua, Rocco Lupoib
Received:
2017-02-17
Revised:
2017-06-10
Accepted:
2017-06-19
Online:
2018-03-20
Published:
2018-03-20
Contact:
Li Wenya
Wenya Li, Kang Yang, Shuo Yin, Xiawei Yang, Yaxin Xu, Rocco Lupoi. Solid-state additive manufacturing and repairing by cold spraying: A review[J]. J. Mater. Sci. Technol., 2018, 34(3): 440-457.
Fig. 4. Schematic diagram of the bonding process of cold-sprayed particles accompanying with the breaking-up and extruding of surface oxide films and the formation of jetting [24].
AM processes | Description in ASTM F2793-12A standard |
---|---|
Material Extrusion | Material is selectively dispensed through a nozzle or orifice |
Material Jetting | Droplets of build material are selectively deposited |
Binder Jetting | A liquid bonding agent is selectively deposited to join powder materials |
Sheet Lamination | Material sheets are bonded to form an object |
Vat Photopolymerisation | Liquid photopolymer in a vat is selectively cured by light-activated polymerisation |
Powder Bed Fusion | Thermal energy selectively fuses regions of a powder bed |
Directed Energy Deposition | Focused thermal energy is used to fuse materials by melting as the material is deposited |
Cold Spraying | Powdered material is propelled at a substrate at a sufficiently high velocity to cause adhesion and material build-up |
Table 1 Names of AM processes described in the ASTM F2793-12A standard [40].
AM processes | Description in ASTM F2793-12A standard |
---|---|
Material Extrusion | Material is selectively dispensed through a nozzle or orifice |
Material Jetting | Droplets of build material are selectively deposited |
Binder Jetting | A liquid bonding agent is selectively deposited to join powder materials |
Sheet Lamination | Material sheets are bonded to form an object |
Vat Photopolymerisation | Liquid photopolymer in a vat is selectively cured by light-activated polymerisation |
Powder Bed Fusion | Thermal energy selectively fuses regions of a powder bed |
Directed Energy Deposition | Focused thermal energy is used to fuse materials by melting as the material is deposited |
Cold Spraying | Powdered material is propelled at a substrate at a sufficiently high velocity to cause adhesion and material build-up |
Fig. 9. EBSD maps and inverse pole figures of the cold-sprayed Cu bulks (a) before and (b) after heat treatment. Noting that the figure in bottom-right corner of (a) shows the corresponding ‘Band Contrast’ [15].
Copper alloys (wt%) | Oxygen content (ppm) | Yield strength (MPa) | Ultimate tensile strength (MPa) | Elongation (%) | Electrical conductivity (% IACS) |
---|---|---|---|---|---|
Pure copper | <200 | 306 ± 10 | 320 ± 5 | 3.0 ± 0.5 | 96.9 ± 0.5 |
Cu-0.1Ag | <200 | 438 ± 10 | 466 ± 5 | 4.04 ± 0.5 | 95.4 ± 0.5 |
Cu-5.7Ag | <200 | 643 ± 10 | 701 ± 5 | 1.25 ± 0.5 | 74.3 ± 0.5 |
Cu-23.7Ag | <200 | 646 ± 10 | 646 ± 5 | 0 ± 0.5 | 62.4 ± 0.5 |
Cu-0.1Ag-0.1Zr | <200 | 442 ± 10 | 483 ± 5 | 7.03 ± 0.5 | 87.8 ± 0.5 |
Cu-3Ag-0.5Zr | <200 | 576 ± 10 | 576 ± 5 | 0 ± 0.5 | 64.4 ± 0.5 |
Table 2 Properties of Cu alloys deposits in the as-sprayed conditions [45].
Copper alloys (wt%) | Oxygen content (ppm) | Yield strength (MPa) | Ultimate tensile strength (MPa) | Elongation (%) | Electrical conductivity (% IACS) |
---|---|---|---|---|---|
Pure copper | <200 | 306 ± 10 | 320 ± 5 | 3.0 ± 0.5 | 96.9 ± 0.5 |
Cu-0.1Ag | <200 | 438 ± 10 | 466 ± 5 | 4.04 ± 0.5 | 95.4 ± 0.5 |
Cu-5.7Ag | <200 | 643 ± 10 | 701 ± 5 | 1.25 ± 0.5 | 74.3 ± 0.5 |
Cu-23.7Ag | <200 | 646 ± 10 | 646 ± 5 | 0 ± 0.5 | 62.4 ± 0.5 |
Cu-0.1Ag-0.1Zr | <200 | 442 ± 10 | 483 ± 5 | 7.03 ± 0.5 | 87.8 ± 0.5 |
Cu-3Ag-0.5Zr | <200 | 576 ± 10 | 576 ± 5 | 0 ± 0.5 | 64.4 ± 0.5 |
Fig. 12. Ultimate tensile strength versus heat treating temperature for cold-sprayed copper alloys (full symbol for binary alloys Cu-0.1Ag (?), Cu-5.7Ag and () Cu-23.7Ag () and open symbol for ternary alloys Cu-0.1Ag-0.1Zr (□) Cu-3Ag-0.5Zr (Δ)) [49].
Fig. 15. (a) Tensile stress-strain curves for cold spraying fabricated commercial pure Ti before and after heat treatment, and corresponding microstructure for (b) as-sprayed and (c) heat-treated deposits [50].
Fig. 17. Typical stress-strain curves for Ti-6Al-4V substrate, helium-sprayed Ti-6Al-4V coatings (as-sprayed and annealed at 600 °C for 2 h), and nitrogen-sprayed Ti-6Al-4V coatings (as-sprayed and annealed at 1000 °C for 4 h) [51].
Fig. 18. Cross sectional microstructures of the (a) Ti and (b) Ti-6Al-4V coatings deposited with pure powder and powder mixtures with different proportions of the shot peening particles [53].
Fig. 23. Ultimate tensile strength (a) and elongation to fracture (b) of microtensile specimens of the CSed Al7075 deposits in the as-deposited and different heat-treatment conditions. The tensile strength and elongation of bulk Al7075 substrate has also been added for comparison [56].
Fig. 27. Optical micrograph of (a) as-sprayed, (b) sintered Inconel 718 (1250 °C × 60 min), (c) flexural strength and strain results for the sintered CS samples [62].
Material | Gas | As-sprayed | Heat-treated | Reference | ||
---|---|---|---|---|---|---|
Tensile strength (MPa) | Elongation (%) | Tensile strength (MPa) | Elongation (%) | |||
Cu | Air | 125 | - | 168 | - | Authors |
N2 | 295 | 0.35 | 220 | 34 | [ | |
He | 300 | 3 | - | - | [ | |
Cu-Ag-Zr | He | 442 | 7.03 | 500 | 8 | [ |
Cu-Ag | He | 438 | 4.04 | 280 | 48 | [ |
Ti | He | 800 | 0.8 | 600 | 13.8 | [ |
Ti-6Al-4V | N2 | 150 | 1.5 | 460 | 5.5 | [ |
He | 480 | 3 | 765 | 6 | [ | |
Al7075 | He | 415 | 3.2 | 560 | 5.6 | [ |
Al6061 | He | 340 | 3 | 200 | 17 | [ |
304L | N2 | 70 | 0 | 360 | 3.5 | [ |
He | 530 | 7.5 | 420 | 22 | [ | |
In718 | N2 | 240 | 0.2 | 570 | 2.4 | [ |
He | 650 | 1 | 800 | 33 | [ |
Table 3 Tensile properties of representative cold-sprayed deposits.
Material | Gas | As-sprayed | Heat-treated | Reference | ||
---|---|---|---|---|---|---|
Tensile strength (MPa) | Elongation (%) | Tensile strength (MPa) | Elongation (%) | |||
Cu | Air | 125 | - | 168 | - | Authors |
N2 | 295 | 0.35 | 220 | 34 | [ | |
He | 300 | 3 | - | - | [ | |
Cu-Ag-Zr | He | 442 | 7.03 | 500 | 8 | [ |
Cu-Ag | He | 438 | 4.04 | 280 | 48 | [ |
Ti | He | 800 | 0.8 | 600 | 13.8 | [ |
Ti-6Al-4V | N2 | 150 | 1.5 | 460 | 5.5 | [ |
He | 480 | 3 | 765 | 6 | [ | |
Al7075 | He | 415 | 3.2 | 560 | 5.6 | [ |
Al6061 | He | 340 | 3 | 200 | 17 | [ |
304L | N2 | 70 | 0 | 360 | 3.5 | [ |
He | 530 | 7.5 | 420 | 22 | [ | |
In718 | N2 | 240 | 0.2 | 570 | 2.4 | [ |
He | 650 | 1 | 800 | 33 | [ |
Fig. 31. Fatigue strength of cold sprayed Al6082 on Al6082 specimens [67]. (AR: As received, CS: Cold sprayed, SP + CS: Shot peening followed by cold spraying, SSP + CS: Severe shot peening followed by cold spraying, CS + SP: Cold spraying followed by shot peening, CS + SSP: Cold spraying followed by severe shot peening.).
Fig. 32. Mean number of cycles prior to failure as a function of the alternating stress obtained from the bending fatigue tests of the bare, alclad, and cold sprayed Al-Co-Ce coating on Al2024-T3 specimens [68].
Fig. 33. Fatigue test results of cold sprayed Ti-6Al-4V on Ti specimens. “Delaminated set” consisted of plasma and cold-sprayed specimens which delaminated spontaneously during the start of fatigue testing [69].
Fig. 35. Repairing of an Al component in a utility engine for a private jet: (a) before with extensive corrosion damage, (b) as-sprayed with aluminum, (c) as-machined and (d) finished part [72].
Fig. 36. (a) Wear rates of repaired specimen and original Al6061-T6, and (b) Comparison of fabricated channels (top view) and cross sections of polystyrol parts made by injection molding [74].
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