You are here Research > RAIL - Robotics & Innovation Lab

Development of Cold Spray towards the next generation Additive Manufacturing

http://www.irishtimes.com/business/research-at-trinity-to-blaze-a-trail-into-3d-printing-of-metal-components-1.2068703

Project coordinator

Dr. Rocco Lupoi
Email: [javascript protected email address]
Tel: +353 1 896 1729

Research Staff

Dr. Barry Aldwell
Email: [javascript protected email address]
Tel: +353 1 896 2396

Post-graduate Staff

A PhD position is currently available. If interested, please email Dr. Lupoi.

Description

Cold Spray (CS) is an innovative coating manufacturing process, which allows for the formation of material layers in a solid-state (free of melting) manner. In this method, the feedstock material (in the form of powder) is injected at the inlet of a converging-diverging supersonic nozzle. The nozzle is fed with high pressure gas (nitrogen or helium), which expands through the internal channel and reaches supersonic speed at the exit (above 1000m/s). Particles are dragged by the fast jet, and upon impact against a substrate material they plastically deform and stay bonded. The density of the coating can be very high, combined with astonishing build rates to approach 250g/min. Also, the solid-state nature of the process allows for the preservation of feedstock properties/micro-structure and the elimination of Heat Affected Zones (HAZ). Typical applications relate to wear resistance, corrosion protection and change of surface properties. Due to the bonding mechanism, not metallurgically compatible combinations are possible such as for the deposition of metals onto polymers and composites for aerospace, automotive and bioengineering applications.

This project aims at developing a unique CS laboratory facility, the first one in Ireland. The programme has raised major interest from the industrial community, with a number of partners who have already contributed to its development.

Cold Spray schematics

Funding Body

European Space Agency (ESA)

Images

Cold Spray processing chamber in TCD (1.7m in height, equipped with a HP powder feeder Uniquecoat PF100WL)

Process area with motorized stages (400x400x200mm).jpg

The X-Y system can incorporate a fully integrated spindle for the processing of round components

WC in-house 200mm long nozzles with CFD prediction of carrier gas velocity (m/s) with nitrogen at 30bar, room temperature

Thick copper coating onto a 40mm aluminium tube

Ti64 aerospace component made of 2 halves and joined with Ti64 CS deposition (leak tight) - ongoing work in collaboration with the University of Twente, Lab of Design, Production and Management