Impact Innovations develops cold spray AM process for Ti6Al4V

December 14, 2020

The Cold Spray additively manufactured Ti-6Al-4V alloy (Impact Innovations GmbH)

Impact Innovations GmbH, Rattenkirchen, Germany, a leading technology provider for industrial cold spray systems and processes, has developed a cold spray Additive Manufacturing process for Ti6Al4V using nitrogen as the propellant.

Cold spray Additive Manufacturing is particularly useful for the production of large parts, which can pose problems for today‘s Powder Bed Fusion (PBF) AM processes due to equipment size limitations or protective atmosphere necessity, especially when depositing reactive materials such as Ti64.

Ti6Al4V is typically used in marine and defence applications, the manufacturing of aerospace structural parts, gas turbine components and biomedical implants and prostheses.

Until now, Ti6Al4V was considered one of the most challenging materials for cold spray deposition due to the high critical velocities the material must withstand during the deposition process, which resulted in porosities in the cold spray deposits of 3% and higher.

Impact Innovations states that its combination of cold spray hardware, process parameters and post-treatment procedure has resulted in porosity levels of < 0.2% and final mechanical properties exceeding the requirements set by the ASTM F3001, ISO 5832-3 and AMS 4930 standards.

In contrast to other Additive Manufacturing technologies, powder particles are not melted during the cold spray process; the bonding occurs due to plastic deformation. Unlike other common AM processes, such as Laser Beam Powder Bed Fusion (PBF-LB), Electron Beam Powder Bed Fusion (PBF-EB) or Wire-Arc Additive Manufacturing (WAAM), cold spraying does not require high temperatures. Thus, it is possible to deposit components without the use of any protective atmosphere, with almost no dimensional limitation, and in the absence of thermal residual stresses. The material efficiency from powder to deposit is more than 97%.

In the latest issue of Metal AM magazine

Download PDF

Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling
  • Inside Wayland Additive: How innovation in electron beam PBF is opening new markets for AM
  • An end-to-end production case study: Leveraging data-driven machine learning and autonomous process control in AM
  • Consolidation, competition, and the cost of certification: Insight from New York’s AM Strategies 2024
  • Scandium’s impact on the Additive Manufacturing of aluminium alloys
  • AM for medical implants: An analysis of the impact of powder reuse in Powder Bed Fusion

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

Discover our magazine archive…

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

  • Reports on visits to leading metal AM part manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

Browse the archive

Looking for AM machines, metal powders or part manufacturing services?

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

  • AM machines
  • Process monitoring & calibration
  • Heat treatment & sintering
  • HIP systems & services
  • Pre- & post-processing technology
  • Powders, powder production and analysis
  • Part manufacturers
  • Consulting, training & market data
View online
Share via
Copy link
Powered by Social Snap