Near-net shape repair of Ti6Al4V thin-walled components by CSAM

The high efficiency of deposition, the density of the material deposited and the possibility of building up or repairing large components are considered the main advantages for Cold Gas Spraying to be introduced as an Additive Manufacturing process (CSAM). By a single movement strategy, called “Metal Knitting”, the authors have demonstrated that this technology allows to control the morphology and geometry of the deposits to a near-net shape situation. This, directly faces one of the constraints associated with this technique when building parts by additive manufacturing. Here, we present a study of the capabilities of Metal Knitting strategy for repairing Ti6Al4V thin-walled structures, i.e. blades or blade-like shaped parts, using CGS. In this work, not only the parameters of the Metal Knitting process have been evaluated and optimized, but also the final parts have been characterized including microstructure analysis, mechanical properties and corrosion and wear resistance evaluation.