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Metals
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Modern Cold Spray Technique—2022
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Modern Cold Spray Technique—2022

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (28 February 2023) | Viewed by 7776

Special Issue Editor

Dr. Alessio Silvello

E-Mail Website
Guest Editor
CPT - Centro de Proyección Térmica (Thermal Spray Center) - Universitat de Barcelona, Barcelona, Spain
Interests: Cold Spray; Additive Manufacturing; Stainless Steel; Ni Based Superalloy; Thermal Spray Process; Mechanical Properties; Fatigue Behavior; Corrosion; Wear.
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Cold spray is becoming more and more prominent among thermal spray processes. The possibility to produce thick coatings with low porosity, as well as the absence of any phase transformation during the deposition process, are of great interest to the scientific community. Further, we should not forget the possibility of spraying any type of materials, from steel to Ti and Ni superalloys, and many more. Not only the microstructural and mechanical properties of the coatings, but also deposition efficiency and geometrical accuracy are key factors for the future success of the process. On these premises, it is no doubt true that cold spray will be the process of the future not only for depositing coatings, but also for producing additive manufactured parts. Consequently, this Special Issue aims to investigate and address the future challenges of cold spray in terms of understanding, improving, modeling, and applying the process in different advanced industrial sectors. Original research articles as well as review papers on the state of the art of the cold spray process are welcome.

Dr. Alessio Silvello
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • cold spray
  • powder metallurgy
  • coatings
  • additive manufacturing
  • modeling
  • wear
  • corrosion
  • fatigue
  • maintenance
  • repair
  • overhaul

Published Papers (4 papers)

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Research

15 pages, 3922 KiB  
Article
Effect of Post-Deposition Thermal Treatments on Tensile Properties of Cold Sprayed Ti6Al4V
by Dibakor Boruah, Xiang Zhang, Philip McNutt, Raja Khan and Henry Begg
Metals 2022, 12(11), 1908; https://doi.org/10.3390/met12111908 - 7 Nov 2022
Cited by 2 | Viewed by 1749
Abstract
This study aims at investigating the effect of various post-deposition thermal treatments on improving tensile properties of cold spray (CS) deposited titanium alloy Ti6Al4V. Dogbone-shaped tensile specimens were designed considering two application scenarios: ‘fully CS’ specimens, and ‘CS repair’ specimens. For both specimen [...] Read more.
This study aims at investigating the effect of various post-deposition thermal treatments on improving tensile properties of cold spray (CS) deposited titanium alloy Ti6Al4V. Dogbone-shaped tensile specimens were designed considering two application scenarios: ‘fully CS’ specimens, and ‘CS repair’ specimens. For both specimen types, tests were carried out in four conditions: (i) as-deposited (AD), and after three different thermal treatments, i.e., (ii) solution treatment and ageing (STA), (iii) hot isostatic pressing (HIP), and (iv) HIP followed by STA (HIP + STA). Complementary to tensile testing, characterisation of CS deposited material was also carried out in terms of microstructure and hardness. The STA process resulted in the highest improvement in ultimate tensile strength by more than 200%, reaching 868 MPa for ‘fully CS’ and 951 MPa for ‘CS repair’ specimens. However, no appreciable improvement in elongation at failure was achieved, highest being 1.2% for ‘fully CS’ after STA, and 4.3% for ‘CS repair’ after HIP. In addition to experimental investigation, a comprehensive collection of data from the open literature on the effect of various thermal treatments on improving the tensile properties of CS Ti6Al4V deposits is reported and discussed. Full article
(This article belongs to the Special Issue Modern Cold Spray Technique—2022)
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23 pages, 11075 KiB  
Article
Thermal Preprocessing of Rapidly Solidified Al 6061 Feedstock for Tunable Cold Spray Additive Manufacturing
by Baillie Haddad, Bryer C. Sousa, Kyle Tsaknopoulos, Victor K. Champagne, Jr., Richard D. Sisson, Jr., Aaron Nardi and Danielle L. Cote
Metals 2022, 12(7), 1214; https://doi.org/10.3390/met12071214 - 18 Jul 2022
Cited by 1 | Viewed by 1756
Abstract
In this work, the influence of thermal pre-processing upon the microstructure and hardness of Al 6061 feedstock powder is considered through the lens of cold spray processing and additive manufacturing. Since solid-state cold spray processes refine and retain microstructural constituents following impact-driven and [...] Read more.
In this work, the influence of thermal pre-processing upon the microstructure and hardness of Al 6061 feedstock powder is considered through the lens of cold spray processing and additive manufacturing. Since solid-state cold spray processes refine and retain microstructural constituents following impact-driven and high-strain rate severe plastic deformation and bonding, thermal pre-processing enables application-driven tuning of the resultant consolidation achieved via microstructural and, therefore, mechanical manipulation of the feedstock prior to use. Microstructural analysis was achieved via X-ray diffraction, scanning electron microscopy, transmission electron microscopy, electron backscatter diffraction, energy dispersive spectroscopy, and differential thermal calorimetry. On the other hand, nanoindentation testing and analysis were relied upon to quantify pre-processing effects and microstructural evolution influences on the resultant hardness as a function of time at 540 °C. In the case of the as-atomized powder, β-Mg2Si-, Al-Fe-, and Mg-Si-type phases were observed along polycrystalline grain boundaries. Furthermore, after a 60 min hold time at 540 °C, Al-Fe-Si-Cr-Mn- and Mg-Si-type intermetallic phases were also observed along grain boundaries. Furthermore, the as-atomized hardness at 250 nm of indentation depth was 1.26 GPa and continuously decreased as a function of hold time until reaching 0.88 GPa after 240 min at 540 °C. Finally, contextualization of the observations with tuning cold spray additive manufacturing part performance via powder pre-processing is presented for through-process and application-minded design. Full article
(This article belongs to the Special Issue Modern Cold Spray Technique—2022)
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12 pages, 5104 KiB  
Article
Abrasion Power of Ti and Ni Diamond-Coated Coatings Deposited by Cold Spray
by Raffaella Sesana, Rocco Lupoi, Irene Pessolano Filos, Pengfei Yu and Sebastiano Rizzo
Metals 2022, 12(7), 1197; https://doi.org/10.3390/met12071197 - 14 Jul 2022
Cited by 1 | Viewed by 1179
Abstract
In this work, the cold spray technique was used to deposit nickel and titanium coated diamond powder on cast iron and aluminum substrates. To analyze the deposition mechanism, the diamond powders were observed before and after the process using a microscope and scanning [...] Read more.
In this work, the cold spray technique was used to deposit nickel and titanium coated diamond powder on cast iron and aluminum substrates. To analyze the deposition mechanism, the diamond powders were observed before and after the process using a microscope and scanning electron microscope (SEM). The adhesion response of the Ni and Ti coatings was investigated during the study. Pin-on-disk tests were then performed to identify the abrasion mechanism of the coated samples and the wear resistance of the Si3N4 ceramic balls. Experimental tests were adopted to determine the significant operating variables, i.e., the local linear speed and the applied load. The modification of the diamond particles in shape, distribution, and the residual debris of Si3N4 on disk were compared before and after the tribological test to analyze the abrasion and wear resistance of the ceramic balls. Full article
(This article belongs to the Special Issue Modern Cold Spray Technique—2022)
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13 pages, 2788 KiB  
Article
Improving the Wear and Corrosion Resistance of Maraging Part Obtained by Cold Gas Spray Additive Manufacturing
by Rodolpho F. Vaz, Alessio Silvello, Vicente Albaladejo, Javier Sanchez and Irene García Cano
Metals 2021, 11(7), 1092; https://doi.org/10.3390/met11071092 - 8 Jul 2021
Cited by 10 | Viewed by 2022
Abstract
The use of the cold gas spray (CGS) process as a metal additive manufacturing (MAM) technique for metallic part production has been deeply studied recently, mainly due to its advantages over other MAM techniques. CGS MAM is a high-productivity technique with a very [...] Read more.
The use of the cold gas spray (CGS) process as a metal additive manufacturing (MAM) technique for metallic part production has been deeply studied recently, mainly due to its advantages over other MAM techniques. CGS MAM is a high-productivity technique with a very low level of particle oxidation, microstructural changes, phase transformations, or deleterious residual thermal stresses in the part. The use of CGS MAM to produce maraging parts represents a gain for the industry by saving machining time and preventing raw material waste. Its wear resistance and corrosion behavior were evaluated in this work and were compared with cermet coatings deposited by high-velocity oxy-fuel (HVOF) on the CGS MAM maraging. This work presents the innovative and effective combination of different thermal spraying processes and materials to obtain MAM maraging parts with higher wear resistance, evaluating abrasion, sliding, and water erosion wear types. Full article
(This article belongs to the Special Issue Modern Cold Spray Technique—2022)
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