Solid State Additive Manufacturing of Titanium Alloys Using Cold Spray

The US Army needs a method for large scale repair and additive manufacture of Ti-6Al-4V components in support of its light weighting initiative. Cold spray metal deposition technology is a solid-state bonding technique where supersonic powdered metal is deposited on a metallic substrate through adiabatic shearing processes at low temperature. Cold spray offers an ideal solution for the Army’s need where adherent, dense, and high strength coatings can be applied at low temperatures in atmosphere, thus mitigating the detrimental effects of high temperature processing including oxidation, warpage, and embrittlement. In this phase II STTR, VRC Metal Systems and the South Dakota School of Mines and Technology, along with our research partner Penn State Applied Research Laboratory, propose to advance cold spray Ti-6Al-4V technology through demonstration of microstructural control and retention, validation of processing windows, enhancement of economic feasibility using alternative processing gas, and demonstration of high rate additive / subtractive capability. This effort will also develop process control solutions for software and in-line inspection, as well as demonstrating cold spray titanium casting repair at TRL7. VRC and SDSM&T will work with our commercialization and transition partners through the effort to establish and mature commercial applications and transition targets.