Sequential Processing of Cold Gas Sprayed Alloys by Milling and Deep Rolling

Area of Science:

• Materials Science
• Manufacturing Engineering
• Surface Engineering

Background:

• Cold gas spraying (CS) is a solid-state process for depositing materials without melting.
• It allows for flexible material composition and component repair or build-up.
• Understanding post-deposition processing effects is crucial for practical applications.

Purpose of the Study:

• To investigate the influence of cold gas spraying on subsequent machining processes.
• To analyze the effects of CS on milling forces and surface topography.
• To evaluate the impact of CS and milling on deep rolling performance and hardness.

Main Methods:

• Cold gas spraying of various materials.
• Machining experiments including milling and deep rolling.
• Measurement of process forces during milling.
• Analysis of surface topography using profilometry.
• Determination of hardness depth profiles using indentation testing.

Main Results:

• Material composition and CS properties (e.g., hardness, particle bonding) significantly influenced milling forces and surface topography.
• Deep rolling did not affect the measured hardness depth profiles for the investigated materials, contrary to expectations.
• The bonding mechanisms in CS layers play a key role in their machinability.

Conclusions:

• Cold gas spraying parameters and material characteristics are critical for successful downstream machining.
• Deep rolling's effectiveness in modifying hardness profiles after CS requires further investigation.
• The study highlights the complex interplay between additive manufacturing via CS and subtractive/formative post-processing techniques.