Temperature and Stress Management in Cold Spraying by Tailored Kinematics
Repair and additive manufacturing applications call for well-adjusted cold spray parameter selection and robot trajectory planning, in order to meet required geometry accuracies and part properties. In addition to the main cold spray parameters like gas pressure and temperature, secondary parameters such as the robot kinematics can have a significant influence. Heat input per unit area in combination with heat transfer parameters determines the effective surface temperature during deposition and the thermal history and stress development in the component during cooling. Hence, understanding the effect of kinematic parameters on local temperature and resulting stress distribution within the cold sprayed components is crucial. In this study, the effect of kinematic parameters such as: nozzle traverse speed, line distance, scanning path pattern and thermal-mechanical constraints have been investigated numerically and calibrated to experimental results. The simulations show that tailored kinematic parameters lead to lower maximum temperatures within the part and more uniform temperature distribution. Thus, more favorable stress states of the finished component can be obtained. This work provides a strategy for thermal and stress management in cold spraying for repair and additive manufacturing applications