Correlating Titanium Powder Manufacturing Methods and Resultant Particle Morphologies to Microstructural Properties, Particle Flight and Impact Velocity, and Bonding and Deposition Characteristics in Cold Spray Additive Manufacturing

Published

January 23, 2025

Author(s)

Pranav Anumandla, Carlos Faggi, Sinan Muftu, Edward Garboczi, Newell Moser, Rachel Cook, Nicholas Derimow, Ozan Ozdemir

Abstract

Unlike high temperature thermal spray processes and metal additive manufacturing methods that require extensive heat treatment, native particle microstructural properties in the feedstock powder have been shown to dictate the final thermomechanical properties of as-deposited cold spray products (e.g., coatings, repairs, free standing parts) in the literature. Recently, particle shape has also been shown to have a significant influence on particle flight and impact velocity in Cold Spray (CS) processes. Thus, powder feedstock thermomechanical properties and size and shape distributions need to be coupled with CS process conditions to understand the direct influence of particle shape on bonding and the significance of the parameter for quality control as CS becomes commercialized in a wider spectrum of industrial applications. Thus, in this study, bonding and deposition characteristics of commercially available titanium (CP-Ti) particles were correlated with their size, shape, and native microstructural properties and their impact velocity and temperature. Gas atomized (mostly spherical), chemically reduced (sponge granules), and chemically reduced and crushed (dense and irregular) powders are characterized for their size, shape, and microstructural properties using optical microscopy, scanning electron microscopy (SEM), laser diffraction particle size analysis (LPA), X-Ray computed tomography (XCT), and electron back scatter diffraction (EBSD) methods. Shadow image particle velocimetry is used for characterizing and dialing CS process parameters for producing single particle splats and thick deposits. Computational fluid dynamics is used for predicting size and shape dependent particle impact velocity difficult to gather using experimental methods. Resultant microstructural properties within particles and bonding interfaces were studied using optical microscopy, SEM, and EBSD. Furthermore, the resultant thermal and mechanical properties were investigated through transient plane source methods, hardness tests, and uniaxial tensile testing.

Proceedings Title

Proceedings of the ASME 2024 International Mechanical Engineering Conference and Exposition

Conference Dates

November 17-21, 2024

Conference Location

Portland, OR, US

Conference Title

ASME 2024 International Mechanical Engineering Conference and Exposition

Pub Type

Conferences

Download Paper

https://doi.org/10.1115/IMECE2024-145643

Local Download

Keywords

cold spray, particle analysis, particle morphology, titanium, impact velocity, additive manufacturing

Citation

Anumandla, P. , Faggi, C. , Muftu, S. , Garboczi, E. , Moser, N. , Cook, R. , Derimow, N. and Ozdemir, O. (2025), Correlating Titanium Powder Manufacturing Methods and Resultant Particle Morphologies to Microstructural Properties, Particle Flight and Impact Velocity, and Bonding and Deposition Characteristics in Cold Spray Additive Manufacturing, Proceedings of the ASME 2024 International Mechanical Engineering Conference and Exposition, Portland, OR, US, [online], https://doi.org/10.1115/IMECE2024-145643, https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=958051 (Accessed April 4, 2025)