Key role of temperature on delamination in solid-state additive manufacturing via supersonic impact

Figures & data

Figure 1. Schematic illustrating the differences between (a) cold spray and (b) warm spray systems [20].

Figure 2. Delamination tends to occur when depositing (a) too thick pure Ni (D_thickness = 13.40 mm) via cold spray. Residual stress analysis for a cold-sprayed pure Ni deposit without delamination (CS-01) showing high residual stress amplitude dependent on delamination: (b) specimen photograph; (c) surface residual stresses obtained by the XRD and contour methods; (d) cross-sectional residual stress mapping through the contour method. CM refers to the contour method.

Figure 3. Specimen photographs showing no delamination of warm-sprayed pure Ni deposits with increasing thickness: (a) WS-01; (b) WS-02; (c) WS-03; (d) WS-04; (e) WS-05. Cutting positions of contour method implementation are marked with red dash-dotted lines.

Figure 4. Residual stress analysis for warm-sprayed pure Ni deposits with increasing thickness in Figure 3 showing the critical role of temperature in lowering residual stress amplitude to avoid delamination: (a) surface residual stresses obtained by the XRD and contour methods; (b–f) cross-sectional residual stress mapping through the contour method.

Figure 5. Schematics of the distribution pattern differences of residual stresses in solid-state additive manufacturing of pure Ni via (a) cold spray and (b) warm spray, illustrating the importance of temperature on delamination.

Kuroda S, Kawakita J, Watanabe M, et al. 7 – Current status and future prospects of warm spray technology. In: Espallargas N, editor. Future development of thermal spray coatings: types, designs, manufacture and applications. Cambridge: Elsevier; 2015. p. 163–206.

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