About this Abstract |
Meeting |
2024 TMS Annual Meeting & Exhibition
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Symposium
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Cold Spray Additive Manufacturing: Part Quality and Performance
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Presentation Title |
Cold Spray Path Planning for Superalloy Structures with High As-deposited Strength and Consolidation |
Author(s) |
Marius D. Ellingsen, Bharat Jasthi |
On-Site Speaker (Planned) |
Marius D. Ellingsen |
Abstract Scope |
Cold Spray Metal Additive Manufacturing is a solid-state process that preserves feedstock alloying conditions. Age-hardenable alloys such as Al6061 can be used as-deposited. Undesired formation of intermetallics is avoided when depositing metal blends, such as when creating gradient deposits. Cold Spray AM of superalloys is attractive because the process is self-peening and creates compressive residual stresses. However, superalloys are challenging to cold spray because they are strong, resisting plastic deformation even at high temperatures. Marginal process conditions result in deposits with significant apparent porosity and low cohesive strength. Heat treatment mitigation is possible but adds expense and time. Creating geometric structures with cold spray adds the challenge of path planning: Incorrect path plans cause erosion or poor deposit quality depending on local geometry. This presentation gives an example of a high-strength superalloy structure with verified properties created using low-cost process gas, optimized process parameters, and optimized path plans. |
Proceedings Inclusion? |
Planned: |
Keywords |
Additive Manufacturing, High-Temperature Materials, Modeling and Simulation |