NIST Award to Support Metal-Based Additive Manufacturing
National Institute of Standards and Technology (NIST) awarded $999,464 to the Cold Spray Research Group in MIE to improve sensing approaches and create a suite of sensor technologies that will help optimize cold spray additive manufacturing (CSAM). Cold spray AM processes have the potential to create parts that are more durable and stronger than those made with other AM processes. New sensors will help characterize the properties of the powder feedstock and the key parameters of the process, such as temperatures and part dimensions, and allow for better control of this promising technique.
This research program will address morphological characterization of metal powders, in-situ gas stream monitoring via acoustic sensing, residual stress control by path planning and, non-destructive, post-print defect characterization. In each one of these categories, novel use of existing measurement systems will be combined with comprehensive modeling approaches.
CS is a solid-state powder consolidation technology where micron-sized powder particles are accelerated to velocity levels of 300 – 1,500 m/s, in a supersonic inert gas. Under the right processing conditions, a fraction of the impact energy enables bonding between the powder particles. Functional, micrometers-to-centimeters thick coatings of metals, ceramics, and polymers can be obtained. Next-generation of CS-machines will be capable of printing non-oxidized, low porosity, low residual stress near net-shape components.