Gleason Matthew A, Sousa Bryer C, Tsaknopoulos Kyle, Grubbs Jack A, Hay Jennifer, Nardi Aaron, Brown Christopher A, Cote Danielle L
Department of Mechanical & Materials Engineering, Worcester Polytechnic Institute, Worcester, MA 01609, USA.
KLA Instruments, Oak Ridge, TN 37830, USA.
Materials (Basel). 2022 Mar 10;15(6):2054. doi: 10.3390/ma15062054.
The surface roughness of additively manufactured (AM) components can have deleterious effects on the properties of the final part, such as corrosion resistance and fatigue life. Modification of the surface finish or parts produced by AM processes, such as cold spray, through methods such as mass finishing, can help to mitigate some of these issues. In this work, the surface evolution of as-produced copper cold sprayed material consolidations was studied through mass finishing. Three different copper powders attained by different production methods and of different sizes were used as feedstock. The surface topography of the cold spray deposits was measured as a function of the mass finishing time for the three copper cold spray samples and analyzed in terms of relative area and complexity, revealing an inverse correlation relating material removal rate and hardness/strength of the cold sprayed deposits. The material removal rate was also affected by the quality of the cold spray deposition, as defined by deposition efficiency (DE). Large initial drops in relative area and complexity are also likely due to the removal of loosely bonded powders at the start of mass finishing. Based on this study, the cold spray parameters that affect the rate of mass finishing have been explored.
增材制造（AM）部件的表面粗糙度会对最终部件的性能产生有害影响，如耐腐蚀性和疲劳寿命。通过诸如 mass finishing 等方法对AM工艺生产的部件（如冷喷涂部件）的表面光洁度进行改性，有助于缓解其中一些问题。在这项工作中，通过mass finishing研究了冷喷涂铜材料固结体的表面演变。使用通过不同生产方法获得的三种不同尺寸的铜粉作为原料。测量了三种铜冷喷涂样品的冷喷涂沉积物的表面形貌随mass finishing时间的变化，并从相对面积和复杂性方面进行了分析，揭示了材料去除率与冷喷涂沉积物的硬度/强度之间的负相关关系。材料去除率还受冷喷涂沉积质量的影响，冷喷涂沉积质量由沉积效率（DE）定义。相对面积和复杂性在开始时的大幅下降也可能归因于mass finishing开始时松散结合粉末的去除。基于这项研究，探索了影响mass finishing速率的冷喷涂参数。
