Additive manufacturing (AM) has the potential to revolutionize industry by reducing the time-to-market and improving the quality of parts while capitalizing on agile, responsive manufacturing techniques with reduced costs. As direct part production is the next step for AM, there is a need for strong support from research and technology organizations (RTOs) to move from rapid prototyping to rapid manufacturing.
Conventional metal additive manufacturing (MAM) technology benefits from many years of development and widespread adoption by multiple industries. However, its low deposition rate presents an often insurmountable hurdle when it comes to manufacturing large parts and prototypes. In comparison, cold spray technology combines high feed rates (currently up to 14 kg/h) with excellent deposition efficiencies on all types of materials and without any heat affected zone, the heat input being very limited. These advantages are the driving force for rapid manufacturing of large components in the aerospace and automotive industries and paving the way toward the development of new applications such as rapid manufacturing of add-ons to existing parts, repair and restoration, structural reinforcement, etc.
What is CSAM
Led by the National Research Council (NRC), the Cold Spray Additive Manufacturing (CSAM) industrial R&D group brings together the technology supply chain, end-users and OEMs in an effort to develop and adapt cold spray for additive manufacturing and demonstrate feasibility for targeted applications. The high-end goal is to have the capability to provide specific integrated solutions for cold spray additive manufacturing applications by 2020. To do so, the objectives of the CSAM group are:
- To bring new cold spray capabilities with improved performance and reliability to address industrial challenges
- To reduce cold spray overall operational cost
- To enhance cold spray automation and mass production capabilities
NRC's Thermal Spray Team is recognized as a world leader in the development of cold spray applications and within NRC, plays the primary research lead in the CSAM group. In addition to this cold-spray expertise, member companies benefit from the experience of more than 30 experts in modeling and simulation, powder metallurgy, process optimization, process control, in-depth characterization, post processing and non-destructive inspection.
Why join CSAM
Members benefit from the competitive advantage of exclusive access to the latest advances in cold spray additive manufacturing.
- Make use of skills and expertise of more than 30 experts that align with your priorities
- Control, minimize and share the risks associated with new technology development
- Steer the R&D roadmap and projects to address actual, economically viable industrial applications and de-risk their validation
- Obtain comprehensive and reliable results that you can adapt to your needs
- Establish a partner network across the entire value chain and advance a sustainable CSAM technology supply chain
- Access to selected NRC background intellectual property and all NRC arising intellectual property as a result of the CSAM R&D projects.
How CSAM works
R&D roadmap-based activities are carried out according to the priorities of CSAM members. Projects are executed by the NRC and the results are delivered to members on a continuous basis through semi-annual general meetings with presentations of all project results, live webinars for project reports and support to individual members. The roadmap is updated regularly based on the advancement of the technology and on the needs and comments of the members.
Project Roadmap and timeline
Long Description of Project Roadmap and timeline
The diagram represents the roadmap and timeline of the project from Year 0 to Year 6−April 2014 to March 2020−to provide specific integrated solutions for cold spray additive manufacturing applications.
Powder Feedstock (in violet)
- Year 2 to Year 5: Commercial powder optimization and qualification
- Year 2 to Year 4: Powder storage, manipulation and preconditioning
- Year 0 to Year 4: Powder modification
- Year 4 to Year 6: Powder cost reduction
Sotware (in green)
- Year 1 to Year 5: Modelling of heating and mass transfer
- Year 1 to Year 5: CSAM toolpath and 3D build up strategy
- Year 5 to Year 6: Software integration
Hardware (in blue)
- Year 0 to Year 6: Diagnostics and sensors (for process monitoring)
- Year 0 to Year 4: Laser and machining assistance
- Year 2 to Year 4: Localized heat treatment
- Year 2 to Year 5: Cold spray systems
- Year 5 to Year 6: Hardware integration
Quality, environment and health and safety (in orange)
- Year 1 to Year 6: Nondestructive inspection (for dimensional and performance assessment)
- Year 2 to Year 5: Review and adaptation of standard environment, health and safety practices
- Year 3 to Year 6: Process quality requirements
Benchmarking and application demonstration (in red)
- Year 2 to Year 3: Deposition process parameter optimization methodology
- Year 2 to Year 6: Benchmarking of deposit properties with developed capabilities and curent knowledge
- Year 0 to Year 6: Application demonstration