April_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 | A P R I L 2 0 2 0 3 9 iTSSe TSS FEATURE INTRODUCTION The global market for 3D printing, or additive manufactur- ing, of metal-based parts was estimated to be US $774 million in 2019 and is projected to reach over US $3 billion by 2024, yielding a compound annual growth rate (CAGR) of 32.5% from 2019 to 2024 [1] with powder bed fusion being the domi- nant technology. Cold spray is a powder metal consolidation technique that has been primarily recognized as a coating pro- cess [2-3] . However, it has core attributes common to conven- tional direct energy deposition metal additive manufacturing (AM), with the important distinction of operating at compara- tively “cold” conditions. Instead of melting the powder or wire, the metal powders in the cold spray process are accelerated to supersonic velocities through a nozzle aimed at the point of deposition. Upon impact of the particles, the high kinetic energy causes plastic deformation for mechanical interlock- ing and metallurgical bonding as a layer of material builds up. Practically, at temperatures far below the melting point, this solid state process prevents undesirable material transforma- tion such as phase changes, oxidation, chemical reactions, or cracking, commonly observed in most metal AM processes in- volving melting and materials undergoing rapid solidification. The low heat input in the cold spray process further reduces thermal load effects on the substrate, enabling repairs with- out inducing undue stresses in the substrates [4-5] . Moreover, it is well suited for multi-material buildups and generates high “build” rates, thus overcoming the slow productivity of conventional AM processing. Finally, the cold spray process operates under normal atmospheric conditions and is there- by inherently scalable to large parts as no inert or vacuum printing environment is required. These characteristics of cold spray give rise to a new degree of freedom to AM that leads to innovation inmanufacturing. Beyond coating applications, cold sprayed deposits have successfully been employed for dimensional restoration, in particular for cast aluminum or magnesium aerospace and defense parts, where worn or corroded material is essentially PolyCSAM: BOOSTING COLD SPRAY ADDITIVE MANUFACTURING INTO FULL-SCALE PRODUCTION A joint Canadian venture launches a new facility with an innovative hybrid approach to cold spray additive manufacturing. Jörg Oberste-Berghaus, Eric Irissou,* and Manuel Martin, National Research Council Canada, Boucherville, QC, Canada Luc Pouliot,* Fernanda Caio, and Sylvain Desaulniers,* Polycontrols Technologies Inc., Brossard, QC, Canada Bruno Monsarrat, National Research Council Canada, Montreal, QC, Canada refilled without affecting the heat sensitive substrate. The high build-up rates in cold spray have also been leveraged for bulk forming, where centimeter thickmaterial is deposited on large structuresor serial productionparts, suchas for sputter targets, induction heating cookware or high power voltage switches, for example. For such applications, one or multiple separate processing steps to post-machine the part to dimension and/ or to post-heat the part to restore material properties is com- monly necessary. Indeed, it is increasingly recognized that the industrialization of cold spray additive manufacturing (CSAM) is rarely viable within the single functionality of the standard cold spray coating process without integrated semi-finishing steps. Appreciating the highly irregular shapes, complexity and variations of casted aerospace parts and the large size of many other components, industrial multi-axis robot based machin- ing and milling is considered the most practical complement to the additive process by virtue of its adaptability, flexibility, and large available work space. PolyCSAM AT A GLANCE Addressing the need for multi-functionality for near-net shaping (Fig. 1) and restoration of large-scale industrial parts, and indeed, integrating in-situ additive and subtractive op- erations in hybrid manufacturing are the main driving forces behind the creation of a new PolyCSAM industrialization fa- cility. This unique technology platform combines multiple *Member of ASM International “OUR MISSION IS TO BOOST COLD SPRAY ADDITIVE MANUFACTURING INTO FULL-SCALE PRODUCTION BY PROVIDING A WORLD CLASS DEMONSTRATOR FACILITY TO MAKE THIS TECHNOLOGY ACCESSIBLE TO POTENTIAL USERS TO ACCELERATE ITS ADOPTION, DERISK IMPLEMENTATION, AND REDUCE TIME TO MARKET.” 5