Cold Spray Additive Manufacturing of Ceramic Composites
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Solution Overview
Problem
Current additive manufacturing methods for high-melting-point materials, such as ceramics and ceramic composites, face challenges including low forming efficiency, high equipment and operating costs, difficulty in achieving full density, and poor surface accuracy, especially for complex-shaped parts with large inclination angles, due to issues like material flow and fall during deposition.
Innovation Solution
A method combining high-speed cold spraying with layer-by-layer deposition and laser shock peening, where the substrate and spray area are preheated to maintain optimal temperatures for deposition, and the formed parts undergo surface modification to generate residual compressive stress, enhancing microstructure and performance while avoiding thermally induced adverse effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser deposition technology is used to melt metal powder layer by layer, then forming precision and workpiece density are improved, but forming efficiency and energy utilization deteriorate
Solution Approach 1:
The patent changes the fundamental parameter of the deposition process by using cold spraying instead of melting. The powder particles are accelerated to supersonic speeds and deposited in a solid state through kinetic energy, rather than being melted and solidified. This parameter change resolves the contradiction by achieving both high forming precision and high forming efficiency without the energy-intensive melting process
Solution Approach 2:
The patent replaces the thermal field (laser melting) with a mechanical field (kinetic energy deposition). By using a cold spraying system where powder particles are accelerated mechanically and deposited through impact, the process achieves high precision without the low efficiency associated with layer-by-layer melting and solidification
2Manufacturing precision
If electron beam freeform fabrication is used in vacuum environment, then forming precision and forming quality are improved, but equipment investment and operating cost increase
Solution Approach 1:
The patent replaces the expensive vacuum chamber and electron beam system with a simpler atmospheric pressure cold spraying system. The deposition process occurs in ambient air using a relatively inexpensive cold spray gun, eliminating the need for costly vacuum equipment while maintaining high forming precision through kinetic energy control
3Productivity
If plasma arc deposition is used to deposit material layer by layer, then forming efficiency and material utilization are improved, but surface accuracy and size accuracy deteriorate
Solution Approach 1:
The patent changes the deposition mechanism from thermal melting (plasma arc) to kinetic energy solid-state deposition (cold spraying). By controlling particle velocity, pressure, and temperature parameters in the cold spraying process, the method achieves both high forming efficiency and high surface accuracy without the need for subsequent machining
4Loss of time
If moldless deposition method is used for complex-shaped parts with large inclination angles, then manufacturing time is reduced, but material flow and fall during deposition occur
Solution Approach 1:
The patent applies preliminary action by pre-heating the substrate and controlling the deposition sequence. The substrate is pre-heated to optimal temperature before deposition begins, and material is deposited in controlled layers that build up support structures before attempting to form overhanging features, preventing material flow and fall
Solution Approach 2:
The patent uses support structures deposited in earlier layers to counteract the gravitational effect on subsequent material. By building up opposing support material first, the method prevents overhanging material from flowing or falling, enabling complex geometries to be formed without sacrificing deposition stability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves manufacturing accuracy, formability, and microstructure of high-melting-point materials, reducing defects like porosity and cracking, and is suitable for producing parts with high surface quality and mechanical properties, suitable for aerospace and energy industries.
Implementation Method 1
The substrate and the spray area are preheated to optimal temperatures for deposition
Implementation Method 2
the formed part is subjected to a surface modification treatment by a laser shock peening method so that the formed part has a predetermined residual compressive stress
Implementation Method 3
performing a layer-by-layer spraying deposition by a cold spraying method according to the computer numerical control codes
Data Source
AI summary
Additive manufacturing (AM) methods and devices for high-melting-point materials are disclosed. In an embodiment, an additive manufacturing method includes the following steps. (S1) Slicing a three-dimensional computer-aided design model of a workpiece into multiple layers according to shape, thickness, and size accuracy requirements, and obtaining data of the multiple layers. (S2) Planning a forming path according to the data of the multiple layers and generating computer numerical control (CNC) codes for forming the multiple layers. (S3) Obtaining a formed part by preheating a substrate, performing a layer-by-layer spraying deposition by a cold spraying method, and heating a spray area to a temperature until the spraying deposition of all sliced layers is completed. (S4) Subjecting the formed part to a surface modification treatment by a laser shock peening method.