July/August_AMP_Digital

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 | J U L Y / A U G U S T 2 0 2 0 6 4 iTSSe TSS iTSSe TSS HYBRID ADDITIVE MANUFACTURING TECHNOLOGY: INDUCTION HEATING COLD SPRAY: PART I (FUNDAMENTALS OF DEPOSITION PROCESS) AND PART II (COATING MECHANICAL PROPERTIES) R. Ortiz-Fernandez and B. Jodoin The prevention of delamination of soft and ductile ma- terials from hard substrates is a challenge when using the cold spray process that is explored in this two-part article. As a potential solution to this issue, a tunable hybrid additive T he Journal of Thermal Spray Technology (JTST), the official journal of the ASM Thermal Spray Society, publishes contributions on all aspects—fundamental and practical—of thermal spray science, including processes, feedstock manufacture, test- ing, and characterization. As the primary vehicle for ther- mal spray information transfer, its mission is to synergize the rapidly advancing thermal spray industry and related industries by presenting research and de- velopment efforts leading to advancements in implementable engineering applications of the technology. Articles from the April and June issues, as selected by JTST Editor-in-Chief Armelle Vardelle, are highlighted here. In addition to the print publication, JTST is available online through springerlink.com. For more information, visit asminternational.org/tss. Fig. 1 — Schematic of the model used to predict the eddy current distribution on the pure aluminum coating. Fig. 2 — Geometry and simulation domain for numerical investigations on the coating process of cylinder bores in crankcases. Visualization of the major boundary conditions. 14 JTST HIGHLIGHTS manufacturing process was developed by coupling induction heating and cold spray processes. Pure aluminum was used as the soft feedstock powder, while Ti-6Al-4V was used for the hard substrate. The effects of induction heating and of the substrate initial temperature on the deposi- tion process were evaluated. Findings demonstrat- ed that substrate preheating has little influence on the overall deposition process and coating qual- ity compared to in situ induction heating effects. Part II of this study evaluated the role of in situ induction heating and substrate preheating tem- perature effects on the coating properties: Micro- hardness, adhesion, and tensile strength were assessed and compared to traditional cold spray coating’s properties. A reduction of up to 20% was found in the coating’s microhardness produced by the hybrid process. These results open up the possibility of using this hy- brid technique as an additive manufacturing process for bulk parts and coating production. (Fig. 1) CFD ENHANCED THERMAL SPRAY PROCESS FOR COATING OF CYLINDER BORES OF CAR ENGINES Bernd Schilder, Andre Garling, Fabian Reimer, Matthias Hamann, Rainer Joos, Jens Hüger, Matthias Pöhlmann, and Thomas Lampke As the automotive industry shifts toward hybrid and al- ternative drive concepts like electromobility, it remains vital to continuously improve internal combustion technology. In- ternal combustion applications represent the largest portion of transportation technologies. Continuous development and improvement of passenger car engines focus on reducing emis- sion by weight reduction and enhanced efficiency. To gain a com- petitive advantage in present and future engines, Mercedes- Benz AG developed NANOSLIDE technology that uses thermal spray technology, i.e., twin wire arc spray, to coat the internal diameterofcylinderbores.Computationalfluiddynamics(CFD) simulation is utilized to investigate the complex gas flow in the cylinder bore of the crankcase during the coating process. Ex- tensive experiments are performed and analyzed to compare the results with the quantitative analysis in order to enhance the properties of the cylinder coating. (Fig. 2)