Feb_March_AMP_Digital

iTSSe TSS A D V A N C E D M A T E R I A L S & P R O C E S S E S | F E B R U A R Y / M A R C H 2 0 1 8 4 3 iTSSe TSS 9 RESEARCH SPOTLIGHT BENEFITS OF COLD SPRAY ADDITIVE MANUFACTURING Cold spray additive manufacturing (AM) advantages in- clude: high build rates up to 10+ kg/h depending on the ma- terial; solid-state deposition with low heat input and lower residual stresses; open air operation using robots to enable buildup on large components; and the capability to build multi-material parts. NRC’s cold spray team is recognized as a world leader in the development of cold spray applications and sees a unique opportunity to convert the technical advan- tages of cold spray into a competitive edge for the manufac- turing industry. CSAM OBJECTIVES In order to adapt cold spray as an AM process, NRC launched CSAM in 2015 as a five-year multi-client precompeti- tive initiative. The main objectives of CSAM are: • • To develop 3D buildup capabilities for cold spray • • To extend the range of materials applicable for cold spray • • To adapt the cold spray process to attain the required deposited material properties for targeted applications As an industrial R&D group, CSAM de-risks the develop- ment of cold spray AMtechnologies (cost sharingandaddition- al leverage from NRC investment), and provides an exclusive edge to its industrial members while advancing a sustainable CSAM technology supply chain. Members have the opportuni- ty to steer the R&D roadmap and projects to address actual, vi- able industrial applications and to establish partner networks across the entire value chain. Membership includes access to all technical and scientific results, project reports, selected NRC background intellectual property, and all NRC intellectual property arising as a result of CSAM activities, including CSAM Digital Solutions Software. R&D PROJECTS Since 2015, 35 projects have either been completed or are now in progress, for a total value of $2.8 million ($3.5 mil- lion CAD). R&D projects are organized through a technology roadmap, which is discussed and updated with CSAM mem- bers, following several research axes: • • Feedstock and powder processing • • Software for cold spray modeling and simulation, 3D buildup simulation, and cost evaluation • • Hardware development and integration • • Diagnostics • • 3D cold spray fabrication (including advanced cold spray capabilities, robot offline programming, and more) • • Benchmarking and application demonstration More than 40 NRC experts are involved in CSAM, with expertise ranging from cold spray to powder metallurgy, mod- eling and simulation, ultrasonic and optical diagnostics, auto- mation, and robotics. ~iTSSe For more information: Interested companies are invited to contact CSAM coordinator Eric Irissou, 450.641.5356, eric. irissou@cnrc-nrc.gc.ca or CSAM project manager Polly-Lee Moore, 450.641.5919, polly-lee.moore@cnrc-nrc.gc.ca or vis- it the CSAM webpage at www.nrc-cnrc.gc.ca/eng/solutions/ collaborative/csam.html. COLD SPRAY ADDITIVE MANUFACTURING INDUSTRIAL R&D GROUP Led by the National Research Council of Canada (NRC), the Cold Spray Additive Manufacturing (CSAM) industrial R&D group brings together the technology supply chain, end users, and OEMs in an effort to develop and adapt cold spray for additive manufacturing and demonstrate feasibility for targeted applications. By combining cold spray digital twinning with advanced robot programming (A and B), it is possible to build 3D structures using cold spray without any masking, i.e., copper cooling fins (C); a copper ring (D); and an “S” shape structure built on the side of a mild steel cylinder (E).