|
5429 |
|
Friday, June 09, 2017, Hall 14 2:20 PM Additive Manufacturing |
|
Experimental and numerical study of the influence of powder characteristics in the cold spraying of Al-based alloys for additive manufacturing using low-pressure, medium-pressure and high-pressure cold spray facilities |
|
Margaux Bunel* / MINES ParisTech, France Francesco Delloro/ MINES ParisTech, PSL Research University, MAT - Centre des Matériaux/C2P, CNRS UMR 7633, France François Borit/ MINES ParisTech, PSL Research University, MAT - Centre des Matériaux/C2P, CNRS UMR 7633, France Michel Jeandin/ MINES ParisTech, PSL Research University, MAT - Centre des Matériaux/C2P, CNRS UMR 7633, France Antoine Bacciochini/ Mallard SA, France Erick Meillot/ CEA Le Ripault, France Kévin Roche/ Dassault Aviation, France Gilles Surdon/ Dassault Aviation, France |
|
Cold spray is continuously expanding for the repair of parts made of aluminum-based alloys, in the aircraft industry in particular. Beyond repair applications, the process is now expected to be exploited efficiently for the additive manufacturing of shaped parts. However, up to now, cold spray is limited to the achievement of rather simple shapes due to a lack of basic knowledge on coating build-up mechanisms to result in dimension-controlled deposition. The objective of the present work is to fill that gap through an experimental and modeling study of the coating build-up in cold spray for this specific application. In the experimental part of the work, Al-based coatings were deposited for a large range of particle velocity due to the use of low-pressure, medium-pressure and high-pressure cold spray facilities. Particle velocity was monitored as a function of cold spray conditions. Two different types of Al 2024 powders were tested. Coating porosity and microhardness were studied as a function of (both morphological and metallurgical) powder characteristics and spray conditions, primarily in the light of particle velocity. Various correlations could be exhibited. In the modeling part of the work, finite element (FE) simulations of particle impacts were developed, which involved particle velocity from experimental measurements. These will be used as inputs in a in-house morphological model, the first stages of which could be established successfully. First results can be considered as promising when compared to experimental microstructures and shapes. |