Cold spray additive manufacturing of 1040 carbon and 316L stainless steel alloys

The use of cold spray (CS) in metal additive manufacturing (AM) offers advantages such as high deposition rate, large working envelope and solid state processing. At the National Research Council, various aspects of the CSAM technology have been investigated in order to address technical challenges that hinder wide adoption for additive manufacturing applications: Powder modification for enhanced sprayability; Laser assistance to improve deposition efficiency and adhesion; Advanced toolpath and build strategies for 3d structures; Software development for process modeling and accelerated parameter optimisation. This presentation focusses on the combination of these technologies to address CSAM of steel alloys such as 1040 carbon steel and 316L stainless steel alloys. The properties of these materials were evaluated through tensile testing and/or other applicable characterization to demonstrate potential applications in repair and reinforcement.