A Comparison of Low and High

Pressure Cold Spray Systems

6/25/2019
Presented by Matt Siopis, PhD
UTRC Team Members: Mike Klecka, Matt Mordasky,
Tim Landry

Portions of this Research w ere sponsored by the Army Research Laboratories and w as accomplished under Cooperative
Agreement Number W911NF-15-2-0034-S9. The views and conclusions contained in this document are those of the authors
and should not be interpreted as representing the official policies, either expressed or implied, of the Army Research
Laboratory or the U.S. Government. The U.S. Government is authorized to reproduce and distribute reprints for government
purposes notw ithstanding any copyright notation herein.
Why Does the Cold Spray System Matter?

 Application Requirements
 Non-Structural: Dimensional restoration
Cost
 Structural: Deposit needs to carry load

 Cost
 Capital Investment Non-
Structural Structural
 Cost per Spray ($ / Volume)

 Misc. Cold Spray System Requirements

 Size, weight, etc.
Current UTC Business Needs
 United Technologies Corporation

 Pratt & Whitney

 Aircraft Engines

 Collins Aerospace
 Aerostructures, Avionics, Interiors,
Mechanical Systems, Mission
Systems, and Power and controls

High Value Structural Repairs

Materials with High Strength and High Ductility
Cold Spray for Non-Structural & Structural Repair
Spray Process Conditions
Low High Low High
Nitrogen Nitrogen Helium Helium

Non-Structural
 Typically for geometry restoration
 Moderate strength
 Low ductility (<1%)
 Lower spray process conditions
 Nitrogen
 Feedstock/Powder
 Pure metals or alloys
 Blends with hard phase
Structural
 Partial load carrying capability
 High strength
 Moderate to high ductility (>5%)
 High spray process conditions
 Helium, high pressure (>35 Bar)
 Feedstock/Powder
 Pure metals or alloys
Cold Spray Process Conditions
TC TC

Powder Injection Site

Nozzle
Carrier Gas /
Powder

Powder Accelerates
Main Gas
Substrate
Path

Main Gas
Path

• Pressurize and heat gas (Nitrogen or Helium)

• Choke the flow and expand gas (Converging – Diverging Nozzle)
• Inject powder upstream or downstream
• Accelerate the powder using aerodynamic drag
 31.11 254 1195 1.9
26.16 230 1283 1.9
Average CVR 22 210 1371 2.0

Process Conditions
Powder Information
Particle density (g/cc)
Particle Specific Heat, Cp J/kg-K
2.64
910
Ma terial
Critical Velocity (m/s)
Critical Veocity Ratio
519
1.2742
1.805
Average Velocity
18.5
15.55
13.08
197
196
210
1459
1543
1623
2.1
2.2
2.4
Max Particle
Particle Size (microns) Particle Velocity Calculator 104.6 Temperature (°C) 430 1143 11 239
Impact Velocity &
1696 2.6
UTS (Mpa)
Process
290 UTS (ksi) Erosion Velocity (m/s) 1038 Powder Particle Average
Gas Selection
Melting
Pressure (bar) Point (°c)
1
40
Process
0 if N2, 1 if He
630
Gas Selection(psi)
Pressure
Pressure (bar)
Type 33
42.1 580 Erosion Velocity
1
40
Ratio 0.637
0 if N2, 1 if He Data
Pressure (psi)
Type 33
580 Distribution Data
Temperature Temperature
Critical Velocity Ratio
Gas Temperature (°C) 430 Output 271
Standoff Distance (in) 1
Gas Temperature (°C) 430 Output
Standoff Distance (in) 1
3.0 0.250
1200 Size %chan
Appl y Remove
Downstream Downstream 0 Powder Distribution Normalized
Type 24 Injection
Type 33 K-Tech Innovati
Injection 0.068 0.078Type
x 24
Type x 0.078
33 x1000 Not Particle Not 2.5 Critical Particle Critical
K-Tech Innovati 0.068 x 0.078 x 0.078 x for Averages* Diameter Fraction
Long 0.2 x 6 0.25 x 6 0.11 x Long Used
0.11-1
Impact Temp
Used Impact Velocity Velocity Impact0.200

m/s & degree K

0.2 x 6 0.25 x 6 x Diameter Impact Temp Velocity Velocity
800 104.6 0.1 (um) 0.001
(°c) (m/s) Ratio (um) (°c) (m/s) Ratio
Mach Number 0.61
Mach Number 87.99 0.006

Critical Velocity Ratio

Nozzle Dimensions at nozzle
Nozzle inlet
Dimensions at nozzle inlet 104.6 -2 387 2.0
662 1.3 104.6 387 662 1.3
Injection 600 1.44 73.99
Throat Diameter (in)Powder Temperature (°c) 0.078 565 Diameter
Throat 0.028 (in) Vp, m/s (at impact) 0.078 662 0.028662 88 Vp, m/s (at impact) 0.014 376 726 1.4 88 376 0.150
726 1.4
Initial Powder Temperature (°c) 430 Expanding
400 -3 62.22 3.49
Expanding 0.035
Exit Diameter (in) 0.196 Exit Diameter
Length(in)(in) Tp, C (at impact) 0.196 387 Tp, C (at impact) Length (in)
387 73.99 362 1.5
794 1.5 73.99 362 794 1.5
Entrance Diameter (in) 0.350 Entrance 4.327
Diameter (in) 0.350 52.32 8.03
4.327 62.22
0.080
346 867 1.5 62.22 346 867 1.5
Expanding 200 -4 44 15.7
Expanding 0.157 0.100
Angle (2Q)
AR / DL Angle
1.459271303
Converging
(2Q)
Length (in) 0.393 37
Ve, m/s (at nozzle exit) 22.94
Degrees628 0.229 1.0 52.32 326 944 1.6
Converging Length (in) 0.393 Degrees 0 (at nozzle exit)
Ve, m/s 628 -5 52.32 326 944 1.6
Area Ratio 6.31
Area Ratio
1.562 Te, C0.00
(at nozzle exit)
0.10
6.31
391 31.11
Te, C (at nozzle exit) 22.77
1.562391
44 0.228 304 1025 1.7
44 304 1025 1.7
Overall Length 4.720.20 0.30 0.40 37 280 1109 1.8
Overall Length 4.72 26.16 14.83 37 0.148 280 1109 1.8
31.11 254 0.050
1195 1.9
nozzle axis, meters 31.11 254 0.5
1195 1.9
particle velocity particle temp 22 6.71 26.16 0.067
230 1283
26.16 230 1283 1.9
nozzle exit gas velocity Average CVR 1.9 22 210 1371 2.0
18.5CVR 2.42
Average 22 0.024 210 1371 2.0
Powder Information gas temp Upper Nozzle
0.0
1.805 18.5 197 1459
0.000
2.1
PowderMaterial being sprayed
Information Particle density (g/cc) 2.64
15.55
Critical Velocity 1.805
(m/s)
0.83
519 18.5 0.008 197 1459 2.1 15.55 196 1543 2.2
Particle density (g/cc) 5056 2.64 2.64 Specific Heat, Cp Critical
630 Velocity (m/s) 290519 Ma terial 13.08
910 Critical Veocity Ratio 0.13 15.55 0.001 196 15430 202.2 40 60 80 100
Particle Ma terial J/kg-K 910 1.2742 Average Velocity 13.08 210 1623 2.4
Particle Specific Heat, Cp J/kg-K 910 Critical Veocity Ratio 1.2742 Average11Velocity
Max Particle 0 13.08 0.000 210 1623 2.4 Paticle Diameter (um)
Particle Size (microns) Max Particle 104.6 Temperature (°C)
total of %
430
100
1143 11 239 1696 2.6
Particle Size (microns) 104.6 UTS (Mpa)
Temperature (°C)
290
430 UTS (ksi) Erosion Velocity 1143
(m/s) 1038 11 239 1696 2.6
* #'s read off microtrac graph
UTS (Mpa) 290 UTS (ksi) Erosion Velocity (m/s) 1038 Average
Critical Velocity Ratio
Melting Point (°c) 630 42.1 Erosion Velocity Average
Ratio 0.637 Temperature
Melting Point (°c) 630 42.1 Erosion Velocity Ratio 0.637 Temperature Critical Velocity Ratio
271
1200 271 3.0 0.250
Appl y Remove Size %chan
Downstream Downstream 0 3.0 Powder Distribution Normalized
0.250
1200 1000 Size %chan
Appl y Remove Injection Injection for Averages* Fraction 2.5
Downstream Downstream 0 Powder Distribution Normalized -1 0.200
1000 m/s & degree K 104.6 0.1 0.001
800
Injection Injection
-1
for Averages*
Impact velocity and temperature are controlled by
Fraction 2.5
87.99 0.61 0.006 0.200

Critical Velocity Ratio

m/s & degree K

104.6 0.1 0.001 -2 2.0

800Powder Temperature (°c)
Injection 565 600 73.99 1.44 0.014 0.150
87.99 0.61 0.006

Critical Velocity Ratio

Injection Powder Temperature (°c) 565
Initial Powder Temperature (°c)
600
430 -2 400 73.99 1.44 process conditions, nozzle geometry, powder
0.014
-3 2.0 62.22
52.32
3.49
8.03
0.035
0.080 0.150 1.5
Initial Powder Temperature (°c) 430
400 -3 200 62.22 3.49 0.035 -4 44 15.7 0.157 0.100
AR / DL
200
1.459271303
-4 0
52.32
44
8.03
15.7
material properties and particle size distribution
0.080
0.157 -5
1.5
37
31.11
22.94
22.77
0.229
0.228 0.100
1.0
0.00 0.10 0.20 0.30 0.40
AR / DL 1.459271303 37 22.94 0.229 1.0 26.16 14.83 0.148 0.050
0 -5 nozzle axis, meters 0.5
0.00 0.10 0.20 0.30 0.40 31.11 22.77
particle velocity 0.228
particle temp 22 6.71 0.067
nozzle
26.16 exit 14.83 gas
0.148 velocity 18.5 2.42 0.024 0.050
nozzle axis, meters gas temp Upper Nozzle 0.5
Material beingparticle
sprayed 22 6.71 0.067 15.55 0.83 0.008 0.0 0.000
velocity particle temp
5056exit
nozzle 2.64
gas velocity 630 18.5 290 910 13.08 0.13 0.001 0 20 40 60 80 100
2.42 0.024
gas temp Upper Nozzle Paticle Diameter (um)
Material being sprayed 15.55 0.83 0.008 0.0 11 0 0.000 0.000
0 total
20 of % 40 100 60 80 100
5056 2.64 630 290 910 13.08 0.13 0.001
* #'s read off microtrac graph
11 0 0.000 Paticle Diameter (um)
total of % 100
* #'s read off microtrac graph
Critical Velocity Ratio
Critical Velocity Critical Velocity Ratio

𝑉𝑖𝑚𝑝𝑎𝑐𝑡
CVR = 𝑉
𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙

T. Schmidt, F. Gartner, H. Assadi, and H. Kreye, Development of a

Generalized Parameter Window for Cold Spray Deposition, Acta
Mater., 51 (2003) 4379-4394.

CVR > 1.0

σUTS Ultimate Tensile Strength
ρ Density
Ti Impact Temperature
TMP Melting Point
CP Specific Heat • CVR is equivalent to the term, η which is used
F1, F2 Empirical Factors in numerous German Cold Spray publications
• CVR > 1.0 can be correlated to improved
ductility in Cold Spray aluminum alloys
Critical Velocity Ratio & Mechanical Properties
Compiled Data from Cold Sprayed Aluminum Alloys
 Compiled Aluminum Alloy Data
 2xxx, 5xxx, 6xxx, 7xxx series

 Powder Feedstock
 Preprocessed (HT, Classified)

 Critical Velocity Ratio (CVR)

 = 1.0 results in bonding
 > 1.0 improved ductility

 Structural Repair
 Higher CVRs, >1.21
Case Study: Cold Spray for Structural Repair
 Compare three Cold Spray OEM systems
 Centerline
 Inovati
 VRC Metal Systems

 Assumptions
 Spraying a 6061 aluminum alloy for structural repair
 Material has been preprocessed and classified
 Process gas is Helium
 Nozzle geometry is defined by each OEM
 Process temperature is limited by nozzle material, PBI at 450°C
 Process pressure is limited by OEM system capability

 Evaluate Critical Velocity Ratio capability and cost of each system

Cold Spray OEM – Centerline SST

Centerline – SST
 EPX System
 Automatic Spray Gun (50 lbs)
 100 – 500 psi (7 – 35 Bar)
 RT – 550°C
 Helium, Nitrogen, or Air
 Dimensions: 27” x 22” x 44”

 PX System
 Manual (4.5 lbs) or Automatic (5 lbs) Spray Guns
 100 – 250 psi (7 – 17.2 Bar)
 RT – 550°C
 Helium, Nitrogen, or Air FEEDSTOCK
 Dimensions: 23” x 20” x 44”
Centerline
SST-A5012: AA6061 Powder
$127 per pound
Cold Spray OEM – Inovati

Inovati
 KM Coating Development System – HDR
 KM Raster Gun (5 lbs)
 50 – 130 psig (3.4 – 9 Bar)
 RT – 1000°C
 Helium, Nitrogen, or He/N2 mixture

 Spray Enclosure
 Dimensions: 62” x 62” x 76”

FEEDSTOCK
Inovati
6061 Powder
$126 per pound
Cold Spray OEM – VRC Metal Systems
VRC Metal Systems
 Gen III Gen III
 Nozzle Applicator (4.4 lbs)
 80 – 1000 psig (5.5 – 69 Bar)
 RT – 800°C @ heater
 Helium or Nitrogen
 Dimensions: 72” x 34” x 72”

 Raptor
 Nozzle Applicator (4.4 lbs) Raptor Dragon Fly
 80 – 1000 psig (5.5 – 69 Bar)
 RT – 800°C @ heater
 Helium or Nitrogen
 Dimensions: 68” x 32” x 65”

 Dragon Fly
 Nozzle Applicator (4.4 lbs)
 80 – 1000 psig (5.5 – 69 Bar)
 RT – 800°C @ heater FEEDSTOCK
 Helium or Nitrogen Solvus Global – Powders on Demand
 Dimensions: 12” x 22” x 40” (2x) SAAM-AL6061-G1H1
28” x 16” x 13” (1x) $125 per pound
Cold Spray System vs. CVR, Helium
Cold Sprayed Aluminum Alloys

10%
5%
3%

CVR of 1.13, ~3% elongation

CVR of 1.23, ~5% elongation

CVR of 1.36, ~10% elongation

Cold Spray System vs. CVR, Helium vs. Nitrogen
Cold Sprayed Aluminum Alloys

Nitrogen
Helium

10%
5%
3%

CVR of 1.13, ~3% elongation

CVR of 1.23, ~5% elongation

CVR of 1.36, ~10% elongation

Cold Spray System CVR vs. Cost
Cold Sprayed Aluminum Alloys

VRC VRC VRC

Dragon Fly Raptor Gen III

10%
5%
3% Centerline
EPX
Inovati
KM CDS

CVR of 1.13, ~3% elongation

CVR of 1.23, ~5% elongation

CVR of 1.36, ~10% elongation

Summary
 There is a need for structural repair of high value aerospace parts
 Spray process conditions and powder feedstock are key to structural
repair
 High pressure cold spray systems are necessary to achieve the CVRs
(critical velocity ratios) required for structural repair
 Cold spray system capability and capital cost should be considered
before purchasing a system
Thank You