High pressure (HP) cold spray (CS) is superior to low pressure cold spray and will be developed into an additive manufacturing method for GRCop-42 with the means of gradually transitioning to another material.
HP CS is a solid-state method that creates deposits with low porosity, high strength, and compressive residual stresses, avoiding problems from melting and resolidification of feedstock such as oxidation, inclusions, hot tearing, cracking, and alloying element segregation. Grain structures tend to be highly refined, promoting good mechanical properties.
HP cold spray is not adapted to freeform additive manufacturing so the proposed work will address this. Thick deposits form an “angle of repose” unique to each material and in Phase I spray strategies to achieve straight-walled simple geometries of GRCop-42 will be developed. The focus will be on nozzle angle and positioning as the deposit builds; the movement parameters will be key for future efforts to automate the process.
Concepts for further development in Phase II will be generated while the ability to transition from GRCop-42 to another material will be demonstrated using ongoing developments at VRC.
TA 12 Materials, Structures, Mechanical Systems and Manufacturing
H5.02 Hot Structure Technology for Aerospace Vehicles
Z3.03 Development of Material Joining Technologies and Large-Scale Additive Manufacturing Processes for On-Orbit Manufacturing and Construction