A Review on Material Dynamics in Cold Spray Additive Manufacturing: Bonding, Stress, and Structural Evolution in Metals

被引：1
作者：
Kafle, Abishek [1 ]
Lu, Shengjun [1 ]
Silwal, Raman [1 ]
Zhu, Weihang [1 ,2 ,3 ,4 ]
机构：
[1] Univ Houston, Dept Mech & Aerosp Engn, Houston, TX 77204 USA
[2] Univ Houston, Dept Engn Technol, Houston, TX 77204 USA
[3] Univ Houston, Dept Ind Engn, Houston, TX 77204 USA
[4] Univ Houston, Dept Elect & Comp Engn, Houston, TX 77204 USA
来源：
METALS | 2025年 / 15卷 / 02期
基金：
美国农业部; 美国国家科学基金会;
关键词：
cold spray additive manufacturing; cold spray materials; residual stress; microstructure formation; phase transformations; ADIABATIC SHEAR INSTABILITY; MICROSTRUCTURAL EVOLUTION; MECHANICAL-PROPERTIES; GRAIN-REFINEMENT; RESIDUAL-STRESS; COATINGS; AL; DEFORMATION; INTERFACE; VELOCITY;
D O I：
10.3390/met15020187
中图分类号：
T [工业技术];
学科分类号：
08 ;
摘要：
CSAM is a solid-state process for depositing metal or metal-based composite materials in which the fine particles of metal or composite material are accelerated to supersonic velocity, making successful bonding feasible due to the high-impact velocity and heavy plastic deformation, all without the melting of the feedstock material. This review examines the basic CSAM mechanism, including deposition dynamics, bonding mechanism, dynamic recrystallization, residual stress evolution, and post-spray heat treatments which affect microstructural and mechanical properties. Although controlled by a few key factors like particle velocity, strain rate, and temperature rise, the bonding efficiency itself refines the grains through dynamic recrystallization, hence improving coating strength and performance. The predominating compressive residual stresses that enhance fatigue resistance and mitigation strategies to improve coating durability by post-spray annealing and laser peening are discussed. This review, by providing an overview of material behavior, optimization techniques, and advanced modeling approaches, underlines the CSAM potential for high-performance applications in aerospace, biomedical industries, and machinery. It further underlines its importance for the advancement of manufacturing innovation and materials science.
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页数：20
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