Build large parts with cold spraying for additive manufacturing
Cold spraying is a coating deposition method, where fine powder particles are accelerated in a high-velocity gas stream. During impact with the object, the particles deform and bond together, creating a layer on the surface. To achieve a consistent thickness, the spraying nozzle is moved repeatedly along the object. A deposit is building up layer-by-layer, to form a part or component.
The cold spray additive manufacturing process differs from selective laser melting or electron-beam additive manufacturing where the feedstock is melted. With cold spray additive manufacturing no melting of the metal powder occurs, since it is a solid-state coating deposition process. There is no heat-related distortion and no special protective atmosphere is required. This enables to build up structures layer-by-layer, thus allowing very large objects to be built or repaired.
Metals and metal matrix composite materials are types of powders than can be deposited using cold spray additive manufacturing.