iTSSe TSS ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2024 51 iTSSe TSS 7 large near-net shape manufacturing, and multi-layer/multi- material builds. Major successes for CS to date include restoration and repair of metal damage from impact, wear, erosion, and corrosion, as well as replacement of legacy coatings with cold spray functional coatings across multiple industries including aerospace, mining, rail, marine, energy, oil, and gas. These achievements have led to enhanced equipment availability, significant cost savings from repair versus replacement, and new functional coatings for corrosion resistance and wear[5]. This is especially relevant given the estimated $2.5 trillion annual cost of corrosion[6]. The global cold spray technology market is anticipated to reach $1.6 billion by 2030, driven by its adoption across various industries. This growth can be attributed to the ability to provide efficient coating and repair solutions and to enhance productivity and performance in diverse applications[7]. NEXT-GEN ADDITIVE MANUFACTURING Cold spray additive manufacturing (CSAM) offers unique advantages, such as shorter production times (high deposition rate), unlimited product size, reduced thermal effects, and high adaptability to different materials compared to commonly used fusion-based AM tech- nologies. This has made CSAM the technology of choice for large-scale, high-performance material net shapes, particularly for complex shapes and thin wall structures. CS is also suitable for fabricating components made of high-reflectivity metals that are typically difficult to manufacture using laser-based AM processes, earning it the designation of “next-generation additive manufacturing”[8]. Advancements in CSAM, particularly in understanding process variables like powder morphology and chemistry, particle velocity, and deposition strategies, have led to improvements in pre- and post-processing techniques crucial for enhancing the properties and performance of the final product. Notable achievements include thermal treatment and hot isostatic pressing to improve mechanical properties and reduce residual stresses in deposited structures. Another post-processing technique that has gained attention is surface finishing, which involves machining or polishing the deposited structure to achieve the desired surface roughness and finish. These post-processing techniques have enabled production of high-quality parts and coatings with improved mechanical properties and surface finish, making CSAM a promising technology for various applications such as aerospace, automotive, and biomedical engineering. Additionally, CS has demonstrated the ability to vary the performance of deposited materials using the same feedstock. One of the significant benefits of the CS process On-site engine repair. Cold spray is used to apply layers of specialty metals to repair an engine section. Engine repair after cleaning. FEATURE
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