Clogging prediction and related failure prevention in Cold Spray large scale additive manufacturing

Cold spray additive manufacturing (CSAM) is a rapidly emerging tool for building large manufacturing components with a complex structure and other features not easily realized by more traditional techniques.

One major challenge in the adaptation is the long duration of the process, combined with the natural instability of the cold spray environment. We suggest the use of online plume monitoring to counter this problem. Recent improvements in cold spray plume sensors have made this a feasible option.

The use case discussed in this presentation is to employ Oseir HiWatch CS-Q particle sensor for nozzle clogging prediction in Inconel alloy CSAM process, which has been successfully realized in laboratory settings and planned for production use in the near future.