Geometric Design for Cold Spray Additive Manufacturing of Aluminum Components

Cold Spray Additive Manufacturing (CSAM) is an emerging metal additive manufacturing technology gaining attention for its capability to print large components at high deposition rates. The benefit of Cold Spray over other AM methods is that the powder does not undergo a phase change to achieve deposition, such as arc-melting with the “wire arc additive manufacturing” process or laser-melting with the “powder-blown directed energy deposition” process. Cold spray utilizes a high-pressure carrier gas to accelerate metal particles to super-sonic speeds such that stable deposition can occur in a layer-to-layer fashion. This unique method offers many benefits but also comes with limitations namely in the form of geometric constraints. This presentation will discuss the constraints and modifications necessary to produce a viable component build strategy. In this case-study, we used a SPEE3D WarpSpeed Cold Spray printer and its proprietary TwinSpeed software to generate robotic path planning and simulations to evaluate part geometry feasibility. In addition, parts were fabricated and then analyzed for porosity using optical microscopy and MicroCT on key features to better understand any interior defects that may have formed.