Author: Ashton Lyon
Advisors: Dr. Danielle Cote , Dr. Kyle Tsaknopoulos
Category: Graduate
Abstract: 3D-printing with metals, using a process such as Cold Spray Additive Manufacturing to build up layers in the shape of a desired metal part, has proven to be a highly green process which enables the repair of worn parts and saves material when manufacturing new parts compared to traditional methods. The material efficiency of cold spray is very high for soft metals such as pure aluminum or copper, with nearly 100% of the material successfully depositing on the workpiece. Refractory metals (Ti, W, Nb) and nickel-based alloys are desirable for their higher strength and heat resistance but are expensive, refined from ore often sourced from conflict mining sources outside the United States, and may only deposit a small fraction of the material spent due to their high hardness. Rather than classifying this valuable powder as waste, the common industry practice today, an opportunity exists to collect, examine, and process this powder for re-use in cold spray printing. This work aims to recover Inconel 718 powder after cold spray for characterization and processing, ultimately finding that heat treatment of recovered powder has successfully reconditioned it for potential re-use in further cold spray, saving valuable material while reducing our waste and overall consumption of these critical metals.
UN SDGs:
SDG 9 – Industry, Innovation and Infrastructure
SDG 12 – Responsible Consumption and Production
Video Presentation:
Poster Presentation:
