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Meeting MS&T25: Materials Science & Technology
Symposium Additive Manufacturing of Thick Films Using Dry Aerosol Processes: Process Development, Materials, Process Optimization and Applications
Sponsorship TMS: Additive Manufacturing Committee
Organizer(s) Desi Kovar, University Of Texas At Austin
Shannon Murray, Sandia National Laboratories
Michael Gammage, CCDC Army Research Laboratory
Scope Cold spray is a high pressure, dry aerosol process that is increasingly used to produce metallic and metal-ceramic thick films. Lower pressure aerosol processes (aerosol deposition, vacuum kinetic spraying, low pressure cold spray, micro-cold spray) are being studied to deposit ceramic and metallic films. Although the deposition of some ductile metals is routine using cold spray, harder materials remain a challenge. Deposition efficiencies are often extremely low (<10%) for low pressure aerosol deposition processes. The deposition of polymeric films or polymer-composite films also remains challenging. In many cases the fundamental mechanisms that are responsible for film deposition are not known. As a result, many trial and error experiments are often required to achieve successful deposition. Improvements in film quality and deposition efficiency may be achieved with a better understanding of film deposition.

This symposium will highlight recent advances in our understanding of aerosol deposition processes. The topics of presentations are sought to include but not limited to:

1. Improved process design including but not limited to advances in nozzle design, deagglomeration, and engineering of powder morphologies for improved film deposition and quality.

2. Computational and experimental investigations using molecular dynamics and finite element modelling, and in situ and ex situ characterization to study nano- and micro-scale film morphologies, crystallinity, porosity, surface roughness, and structural and functional properties for films deposited via aerosol processes.

3. Computational and experimental investigations to study gas flow, gas-particle, and gas-substrate interactions during aerosol deposition
4. Applications of machine learning and deep learning to aerosol processes.

5. Novel applications enabled by aerosol processes.

Abstracts Due 05/01/2025
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