CSAM : Cold spray additive manufacturing

Abstract

Cold spray additive manufacturing is a solid-state deposition technique that has evolved from a coating technique to a viable additive manufacturing method. It uses heated gas, like helium, nitrogen or air to accelerate particles towards a substrate material. The particles adhere through plastic deformation, so the thermal effects on the underlying material are minimal, which makes the process ideal for thermally sensitive materials. Some of cold spray additive manufacturing’s advantages are the unlimited build size, process portability and the ability to work on highly reflective materials. It faces challenges when it comes to the dimensional accuracy of the parts manufactured and the material properties of the parts manufactured. Its ability to manufacture alloys has made it lucrative for various industries such as the aerospace industry. When compared to other popular additive manufacturing techniques such as laser powder bed fusion and laser directed energy deposition, it stands out with its portability and minimal thermal impact. It lacks behind with its dimensional accuracy and initial material properties, but these can be improved with post processing. Currently it’s a great choice for repair applications and with further research it could become a viable option in part fabrication.