Solid-State Cold Spray Additive Manufacturing of Ni-Based Superalloys: Processing-Microstructure-Property...

Area of Science:

• Materials Science and Engineering
• Additive Manufacturing
• Aerospace Materials

Background:

• Ni-based superalloys are critical in aerospace due to high-temperature stability.
• Fusion-reliant additive manufacturing (AM) methods for these alloys suffer from defects like oxidation, cracking, and segregation.
• A need exists for AM techniques that overcome these limitations.

Purpose of the Study:

• To evaluate cold spray (CS) as an alternative AM technique for Ni-based superalloys.
• To compare the advantages of CS with traditional fusion-based AM.
• To elucidate the processing-structure-property relationships of CS Ni-based superalloy deposits.

Main Methods:

• Review of existing literature on cold spray (CS) for Ni-based superalloys.
• Analysis of microstructural, mechanical, and tribological properties of CS deposits.
• Examination of post-processing techniques to address CS-specific defects (porosity, brittleness).

Main Results:

• CS offers a cost-effective, low-temperature, and clean deposition process for Ni-based superalloys.
• Understanding of processing-structure-property correlations in CS Ni-based superalloys is established.
• Post-processing methods are identified to mitigate porosity and brittleness in CS coatings.

Conclusions:

• Cold spray (CS) presents a viable alternative to fusion AM for Ni-based superalloys, mitigating common defects.
• Further research is needed to fully optimize CS processing and post-processing for superior structural performance.
• This review provides a foundation for future investigations into CS Ni-based superalloys.