A sustainable ecofriendly additive manufacturing approach of repairing and coating on the substrate: cold spray

ABSTRACT

In this study, surface modification and deformation behaviour of different engineering materials were microscopically examined by an approach called cold spray additive manufacturing (CSAM). The CSAM is a layer-by-layer deposition technique for repairing and coating the deteriorated or dimensionally unstable surface. Furthermore, in this study, both the experimental and numerical investigation have been carried to understand the surface modification approach. In the experimental procedure, the de Laval nozzle accelerates the microsize particle at a high velocity on the substrate to obtain the uniform surface coating. Engineering materials like copper, aluminium, titanium and mild steel were probed with different ranges of velocities. Additionally, an explicit/Abaqus finite element approach was used to investigate the bonding between particle and substrate by using the high velocity of particles. At the interface, refining meshing size reduces the beginning velocity for adiabatic shear instability (ASI). For the different combinations of particles and substrates like copper/copper, aluminium/aluminium, titanium/aluminium, aluminium/ titanium, and copper/mild steel at perpendicular impact, the adiabatic shear instability was numerically estimated. Deformation behaviour for multi-impact has also been seen with different particle diameter sizes to determine coating phenomenon. Furthermore, the characterisation technique called scanning electron microscopy (SEM) also showed the uniform coating on the substrate.

KEYWORDS:

• Cold gas dynamic spray
• additive manufacturing
• scanning electron microscopy
• numerical simulation
• critical velocity

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data Availability Statement

The authors confirm that the data supporting the findings of this study is given within the article.

Additional information

Notes on contributors

Abdul Faheem

Abdul Faheem is an Assistant Professor in the Mechanical Engineering Section, University Polytechnic, AMU, Aligarh. He obtained his M.Tech in Industrial and Production from Zakir Husain College of Engineering and Technology. He has contributed to different journals and conferences on subjects related to Mechanical Engineering. His field of interest – Additive Manufacturing, Surface Engineering, Friction stir welding, and computational manufacturing. He received the best paper award in the international conference on computational methods on manufacturing at IIT Guwahati, India, 2019.

Ankit Tyagi

Ankit Tyagi is an Assistant Professor in the Department of Mechanical Engineering, SGT University, Haryana, India. He is pursuing his PhD in the area of manufacturing process in advance coating, Delhi Technological University, India. He visited various academic institutions and industries at several countries towards academic pursuits. His area of research includes, Surface Modification, Coating, Tribology, Material Processing; Composite Materials; Metal Matrix Nanocomposites; Nano-Coatings; Wear; Deformation and Corrosion. He also has a good command over teaching subjects like Welding Technology, Casting, Wear Mechanics, Material Science, Non-Destructive Testing, Metrology and Composite Materials. He has published more than 30 research papers in reputed journals and conference proceedings.

S. M. Pandey

SM Pandey is an assistant professor in the Department of Mechanical Engineering, NIT, Patna, India. He got his PhD (2017) in the area of manufacturing process in advance coating, Delhi Technological University, India. He worked also as assistant Professor at Delhi Technological University, Delhi, India. His area of research includes, Surface Modification, Coating, Tribology, Material Processing; Composite Materials; Metal Matrix Nanocomposites; Nano-Coatings; Wear; Deformation and Corrosion. He also has a good command over teaching subjects like Welding Technology, Casting, Wear Mechanics, Material Science, Non-Destructive Testing, Metrology and Composite Materials. Dr. Pandey has over 02 year of Industry Experience in the SPRL Ghaziabad in the field of Production Planning and Control and 8.5 plus years of teaching and research in various reputed organization as Delhi Technological University and NIT Patna. In this period of time he has published 10 research papers in peer reviewed international journals having good impact factor and 13 research papers in reputed international and national conferences in India as well as in abroad. Apart from this recently he has also published 01 chapters in books published by Springer. 09 students have completed their B. Tech projects and 06 students have completed their M.Tech dissertation under his guidance.

Faisal Hasan

Faisal Hasan obtained his Ph.D. in the area of Reconfigurable Manufacturing System from Indian Institute of Technology Roorkee. Joined as Faculty in the Department of Mechanical Engineering, AMU in 2003. Teaching and research interests includes Manufacturing Systems, Human Factors and Operations Management. He has published papers in various International journals like Opsearch, Occupational Ergonomics, Work, International Journal of Industrial and Systems Engineering, and International Journal of Operations Management. Also attended and presented papers at various international and national conferences.

Qasim Murtaza

Qasim Murtaza is a Professor in the Department of Mechanical Engineering, Delhi Technological University, Delhi (Erstwhile Delhi College of Engineering). He got his PhD (2006) in the area of manufacturing process, Dublin City University, Ireland. He worked also as Research Associate at Metropolitan Manchester University, Manchester, UK. He visited various academic institutions and industries at several countries towards academic pursuits. His research interest includes Precision Manufacturing and Advanced Manufacturing Processes such as Metal coatings, Free-standing metal coating components, Hybrid stir casting & including tribological assessment, Super-finishing processes and Re-manufacturing. He guided 33 M.Tech thesis and 7 PhDs. He has published more than 97 research papers in reputed journals and conference proceedings and got best paper award from Elsevier, Emerald and Springer publication house. He shared interview board as expert member in public sector companies, govt. service commissions and also worked on the examination/research boards of various institutions and involved in multiple institutional activities related to policy planning, curriculum design, admission, evaluation & examination and another academic process.