Cold Spray Repair of Reactive Metals: A Sustainable Alternative to Vacuum Arc Remelting

Cold Spray Repair of Reactive Metals: A Sustainable Alternative to Vacuum Arc Remelting. This research investigates the economic and environmental benefits of cold spray repair for titanium components in comparison to the production of new parts using the conventional remelting process for scrap titanium, specifically vacuum arc remelting (VAR). Titanium’s high material cost and energy-intensive production make efficient repair methods crucial for reducing both operational expenses and environmental impact in industries such as hydrometallurgy, aerospace, and defense. Cold spray technology offers a cost-effective alternative by enabling localized repair of worn or damaged titanium parts without the need for replacement parts formed by remelting titanium scrap metal, thereby significantly lowering both CO2 emissions and energy consumption. In this study, we provide a comparative analysis between cold spray repair of wear components and VAR of replacement components, highlighting the reduction in energy usage, greenhouse gas emissions, and overall costs. The findings underscore the potential for cold spray technology to improve the sustainability of titanium part maintenance while offering considerable economic savings, positioning it as a favorable alternative for the repair of reactive metal components.