Cold Spray Deposition of Superalloys for Additive Manufacturing

Cold spray technology is a well-established deposition technique to produce dense metallic coatings and can confer solutions in various industrial fields. Last developments show capabilities of complex structure fabrication by additive manufacturing for aircraft applications.

This study describes the deposition of several superalloys by cold spray.

On the one hand, determination and analysis of the critical velocity were performed using DPV 2000 in link with the coatings properties (porosity, cohesion, hardness, mechanical properties…).

On the other hand, residual stress measurements were performed using the In-situ Coating Property sensor (ICP) from Reliacoat Technologies. The sensor allows the determination of the in-situ residual stress evolution during the deposition process. The residual stress measurement is based on the sample curvature.

Most studies with ICP sensor were carried out for plasma-sprayed coatings. This work evaluates the possibility to use it for the development of cold-sprayed coatings, in order to optimize the spraying parameters and to deepen the understanding of residual stress generation.