Cold spray additive manufacturing (CSAM) is a coating deposition method where a high velocity gas stream is utilized to deposit particles upon a substrate at low temperatures relative to the melting point of the alloy being deposited. During impact, the particles undergo plastic deformation and adhere to the surface in the solid state. Fully dense metal AM parts are built layer by layer by controlling the movements of the nozzle.
Advantages of Cold spray additive manufacturing (CSAM) technology
The main advantage of the cold spray process are immense deposition rates along with the ability to deposit near all metal and alloy powders. With CSAM technology, it is feasible to combine dissimilar materials for bimetallics. Components manufactured by CSAM technology are high density and homogenous.
Disadvantages of Cold spray additive manufacturing (CSAM) technology
CSAM is considered a near net shape technology for most applications, meaning sharp corners, tight tolerance dimensions or smooth surfaces will need to be machined. The physics of the process does not allow for tall thin features or walls. The process can form tall features if they are tapered with a wider base for stability. Other concerns may include restrictive part geometry, accuracy and material embrittlement.