The cold spray process produces dense, low oxide coatings which can be used in such diverse applications as corrosion control and metals repair. It has emerged as an important alternative to thermal spray coating techniques in certain areas. This pioneering book reviews both the fundamentals of the process and how it can best be applied in practice. The first part of the book discusses the development of the process together with its advantages and disadvantages in comparison with thermal spray coating techniques. Part 2 reviews key process parameters such as powders, nozzle design, particle temperature and velocity, and particle/substrate interaction. It also describes portable and stationary cold spray systems. The final part of the book discusses how the cold spray process can be applied in such areas as improved wear, corrosion protection, electromagnetic interference shielding and repair of damaged components. The cold spray materials deposition process will be a standard reference on this important process and its industrial applications.
Author(s): D. Champagne
Year: 2007
Language: English
Pages: 377
1845691814......Page 1
Contents......Page 4
Contributor contact details......Page 10
Preface......Page 14
1: Introduction......Page 16
Part I: General issues......Page 24
2.2 Discovery of the cold spray phenomenon and its basic features......Page 26
2.3 Initial studies on the development of cold spray: basic physical principles and key features......Page 36
2.4 Evolution of cold spray technology and current status......Page 49
2.5 Some comments on the patent situation......Page 53
2.6 List of symbols......Page 55
2.7 References......Page 56
3.2 Traditional thermal spray technologies......Page 58
3.3 Comparison of cold spray with traditional thermal spray......Page 67
3.5 References......Page 76
4.1 Introduction......Page 77
4.2 Advantages of the cold spray process......Page 78
4.4 References......Page 85
5.1 Introduction......Page 87
5.2 Cold spray equipment and infrastructure......Page 88
5.3 Consumables......Page 91
5.4 Comparison with other thermal spray techniques......Page 102
5.5 Comparison with other additive fabrication techniques......Page 107
5.6 Conclusions and future trends......Page 112
5.8 References......Page 113
Part II: Cold spray process parameters......Page 118
6.1 Introduction......Page 120
6.2 Selection criteria for cold spray feedstock......Page 121
6.3 Key powder properties......Page 123
6.4 Powder manufacturing process......Page 124
6.5 New material developments......Page 128
6.6 Discussion......Page 129
6.7 Conclusions......Page 130
6.9 References......Page 131
7.1 Introduction......Page 132
7.2 Numerical simulation of the cold spray process......Page 133
7.3 Nozzle design influences......Page 138
7.4 References......Page 140
8.1 Introduction......Page 142
8.2 Particle velocity and temperature......Page 143
8.3 The impact of particle velocity and temperature on coating formation......Page 147
8.4 Altering particle temperature......Page 157
8.7 References......Page 160
9.1 Introduction......Page 163
9.2 Transient non-linear dynamics analysis of the cold-gas particle/substrate interactions......Page 165
9.3 Adiabatic shear instability and plastic-flow localization......Page 179
9.4 The role of interfacial instability......Page 186
9.6 References......Page 191
10.1 Introduction......Page 193
10.2 Investigation of supersonic air jets exhausting from a nozzle......Page 194
10.3 Impact of a supersonic jet on a substrate......Page 203
10.4 Heat transfer between a supersonic plane jet and a substrate under conditions of cold spray......Page 217
10.5 List of symbols......Page 228
10.6 References......Page 230
11.1 State-of-the-art cold spray systems......Page 232
11.2 State-of-the-art powder feeding systems......Page 237
11.3 Modification of the low pressure portable gas dynamic spray system......Page 239
11.5 References......Page 245
12.1 Introduction......Page 247
12.2 Industrial cold gas spray equipment: system layout, gas supply and control cabinet......Page 249
12.3 Industrial cold gas spray equipment: gas heater, powder feeder and cold spray gun......Page 252
12.4 References......Page 256
Part III: Applications of cold spray coatings......Page 258
13.1 Introduction......Page 260
13.2 Materials used for analysis......Page 261
13.3 Mechanical property measurements......Page 262
13.4 Microstructural characterization of coatings......Page 265
13.5 Properties of coatings......Page 266
13.6 Comparison of cold spray coatings with traditional thermal spray coatings......Page 272
13.9 References......Page 276
14.2 Current state of the art......Page 279
14.3 Cold spray wear-resistant material properties......Page 280
14.4 Cold spray wear-resistant processing......Page 285
14.5 Characterization......Page 287
14.6 Powder characteristics......Page 292
14.7 X-ray diffraction and phase analysis......Page 299
14.8 Scanning electron microscopy......Page 303
14.9 Tribology......Page 305
14.10 Adhesion and bond strength......Page 309
14.11 Potential hybrid process combining cold spray and laser processing......Page 310
14.12 Conclusions......Page 312
14.14 References......Page 313
15.1 Introduction......Page 317
15.2 Cold spraying of metals as a coatings technology for corrosion control......Page 319
15.3 Galvanizing of steel structures to prevent corrosion......Page 321
15.4 Preventing aqueous and hot-surface corrosion......Page 324
15.5 Conclusions......Page 326
15.6 References......Page 327
16.1 Introduction......Page 330
16.2 Cold spray particle deposition......Page 332
16.3 Screening tests......Page 333
16.4 Test results......Page 336
16.5 Application......Page 339
16.6 Conclusions......Page 340
16.8 References......Page 341
17.2 Problems in using magnesium components......Page 342
17.3 Limitations of current technologies......Page 344
17.4 Key issues in using the cold spray process......Page 347
17.5 Developing and testing cold spray coating of magnesium......Page 348
17.6 Cold spray technology for coating magnesium......Page 350
17.7 Predictive modeling for process optimization......Page 353
17.8 Cold spray trials......Page 354
17.9 Coating characterization......Page 356
17.10 Cost savings and implementation......Page 364
17.11 Conclusions......Page 365
17.12 References......Page 366
Index......Page 368
