Title: EXPERIMENTAL EVALUATION OF METAL COLD SPRAY ON 3D PRINTED POLYMERS

Authors: Patrick A. Bailey, Wout De Backer

DOI: 10.33599/nasampe/s.23.0181

Abstract: Cold Spray (CS) additive manufacturing utilizes highly pressurized super-heated gasses to spray microscopic particles on a substrate. These microscopic particles encompass a variety of material types including pure metals, and metallic alloys. The kinetic energy of the particles being released upon impact forms adhesive and cohesive bonds between the substrate and powder. Prior literature and experimentation reveal that while CS is beneficial and tested on metallic structures, it’s unproven in its application to polymers like PLA, or PETG. The CS process has been tuned to spray metallic powders on complex 3D printed structures at a discrete temperature range from 200 °C to 600 °C. Tests are conducted on the 3D printed structures to determine their operational interaction ranges with CS metals. At these parameterized ranges, CS is used to test the viability of geometrically complex 3D printed parts as a basis for rapid mold prototyping by spraying over their surfaces and breaking away the polymer. Lastly, 3D printed parts are intentionally damaged, and CS is used to attempt to repair them. Mechanical testing and microscopy analysis show that while more work for processing is needed, CS on polymers is a possible path going forward in the manufacturability and repair field.

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Conference: SAMPE 2023

Publication Date: 2023/04/17

SKU: TP23-0000000181

Pages: 16

Price: $32.00