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Abstract No.: |
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Scheduled at:
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Friday, June 12, 2020, Hall K1 12:20 PM Cold Gas Spraying III
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Title: |
Study of Ni-based cold spray coatings as build platform for laser beam melting additive manufacturing
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Authors: |
Cléa Plouze* / MINES ParisTech, France Vincent Guipont / Mines ParisTech, PSL University, France Lyliat Ferhat/ Mines ParisTech, PSL University, France Antoine Debray/ Mines ParisTech, PSL University, France Francesco Delloro/ Mines ParisTech, PSL University, France Jean-Dominique Bartout/ Mines ParisTech, PSL University, France
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Abstract: |
Cold Spray (CS) is a solid-state powder process mainly developed for metallic coatings. The particles are propelled at high velocity and deform plastically without melting. CS process is able to form thick layers and complex freestanding shapes with high deposition rate. Therefore, CS is an attractive process for Repairing and Additive Manufacturing (R&AM). Laser Beam Melting (LBM) is a powder bed fusion AM process enabling high shaping fidelity, but low deposition rate. With LBM, the powder is molten and solidified incrementally exhibiting dilution and heat-affected zones. In this work, both processes are combined for the manufacturing of LBM build platforms by CS. For such application, the composition is crucial because heat dissipates preferentially through it during LBM. Thus, local distortions or damaging due to heat gradient or thermal expansion mismatch near the junction area have to be managed. Therefore, a similar composition for both build platform and LBM powder is preferred, also to prevent unexpected intermetallic compounds. It is especially important for materials sensitive to hot cracking like Inconel738LC. In this study, Ni-based CS coatings were investigated as potential building platform for IN738LC by LBM. CS coatings with commercial Ni and IN738LC powders were prepared with various spraying parameters involving nitrogen or helium gas and gas temperature up to 600°C. Microstructure, thickness, hardness, porosity, surface morphology were characterised in order to select samples for further LBM experiments. Trials were carried out using a LBM facility (Concept Laser M2 dual) with same IN738LC powder. Single line scanning experiments using different LBM parameters (spot size 100 µm) were implemented in order to evaluate the microstructural and morphological modifications of the CS coating near each dilution and heat affected zones. The influence of heat pre-treatments (200-500°C) of CS coatings before LBM was also investigated.
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