Search Results for deposition rate

This article describes work to develop a cost-efficient plasma gun capable of high deposition rates. Engineers analyzed both gun components and gas flow dynamics to design a gun that improves plasma stability. Considerable effort was spent on characterizing the use of the gun for spraying yttria-stabilized zirconia (YSZ) for thermal barrier applications.

Wire arc directed energy deposition (WDED) is a robust alternative for large-scale metal printing. It offers high deposition rates, excellent material and energy efficiency, and reduced waste material compared to conventional manufacturing processes. This article describes a study that employed a combination of standard and advanced characterization techniques to assess the mechanical behavior of WDED titanium samples. This entry won first place in the light microscopy category of the prestigious 2023 International Metallographic Contest.

This article describes the design and operation of a high-deposition rate plasma nozzle developed for ambient pressure spraying.

Metal additive manufacturing has steadily progressed over the past decade, with today’s directed energy deposition processes enabling rapid builds of large structures in near-net shape—and with minimal machining required to achieve final dimensions.

New thermal spray methods optimized for the production of functional coatings are bridging the gap between traditional thermal spraying and thin-film deposition technologies. Two such methods, one known alternately as very low pressure plasma spraying (VLPPS) or plasma spray-physical vapor deposition (PS-PVD) and one called thin-film thermal spray chemical vapor deposition (CVD), are briefly reviewed here.

This article reports on the development of additive friction stir deposition techniques that use secondary feedstocks such as machine chips and damaged components to make in-field repairs at the point of need. The focus of the initial research was aluminum alloys. Preliminary studies show significant promise for the adaptation of these techniques to hard alloys including steel castings, wrought high strength steels, and titanium alloys.

The next generation of metal additive manufacturing leverages the advantages of cold spray to offer promising options for applications in aerospace, automotive, and biomedical engineering.

The extreme high-speed laser application (EHLA) process offers efficient deposition of high-performance materials in aerospace manufacturing, providing key advantages compared to conventional laser cladding. As a sustainable alternative to chrome plating, EHLA excels in material integrity, efficiency, and performance, while reducing costs compared to thermal spray and conventional laser cladding. This article discusses how EHLA can help to address many sustainability concerns within the manufacturing sector.

A joint Canadian venture launches a new facility with an innovative hybrid approach to cold spray additive manufacturing. The technology platform combines multiple manufacturing steps in a single cold spray additive manufacturing (CSAM) unit, incorporating surface preparation, cold spray forming and buildup, local laser-based thermal treatment, and in-situ sequential robotic machining and semi-finishing.

Vacuum heat treating is a crucial step in the additive manufacturing process cycle to meet required part quality specifications.

The idea of building a part from scratch on a single machine or rebuilding components and assemblies in situ is a radical departure from conventional thinking based on subtractive manufacturing. This article discusses the benefits foreseen with additive or direct digital manufacturing and describes ongoing efforts to accelerate the development and realization of the technology.

Thermal spray technology is increasingly being used in alternative energy applications such as solid-oxide fuel cells, solar panels, and wind and hydropower turbines.

Hybrid heat sinks produced via cold spray technology can be a cost effective and lightweight alternative for cooling electronics.

Although the widespread use of titanium alloys is constrained by high costs, powder metallurgy techniques such as additive manufacturing (AM) represent an economical approach to fabricating titanium components. Various approaches to AM, along with examples of components made by different AM processes, are presented. The microstructures and mechanical properties of Ti-6Al-4V produced by AM are also discussed and compared with cast and wrought products. Finally, the economic advantages of AM compared to conventional processing are presented.

Laser cladding applies thin deposits of hard or corrosion-resistant materials to surfaces susceptible to damage. This article discusses the advantages and drawbacks of laser cladding in comparison to thermal spraying.

Innovations built into a new plasma spray torch address shortcomings of previous axial injection equipment.

One of the most recent success stories for thermal spray in the automotive industry involves the development of plasma transferred wire arc (PTWA) for aluminum engine blocks. Driven by the demand to increase fuel efficiency, automakers are placing emphasis on decreasing overall vehicle weight as well as improving engine efficiency by reducing internal friction losses. The surface structure of the composite coating created by the PTWA process promotes favorable lubrication, low friction, wear resistance, improved heat transfer, and decreased bore distortion in engine block cylinders.

Thin film cathodic arc PVD coatings offer an easy and economical way to optimize surface properties without changing bulk performance. This article describes a modified cathodic arc process called arc plasma acceleration (APA), which enables production of high density, thin film coatings containing minimal macroparticles.

The use of coatings to enhance the performance of components is one of the most powerful tools in materials engineering. This article highlights some examples of how thermal spray technologies are used to enhance surface properties for selected applications and industries.

Thermal barrier coatings (TBCs) with segmented or cracked microstructures exhibit enhanced thermal cyclic behavior and erosion resistance, along with improved application economics, over conventional TBCs.