Cold-Sprayed Ni and NdFeB-Al Powders Recovery and Reuse
Jean-Michel Lamarre, Alexandre Nascimento, Cindy Charbonneau, Luc Pouliot, Fabrice Bernier
TL;DR
This paper explores recovering and reusing powders used in cold spray manufacturing to improve efficiency and reduce waste.
Contribution
A prototype system for powder recovery is developed and tested for Ni and NdFeB-Al powders, showing high recovery efficiency and minimal impact on performance.
Findings
A recovery efficiency of up to 75% was achieved for both Ni and NdFeB-Al powders.
Recovered powders retained sufficient magnetic properties for reuse in coatings.
NdFeB-Al mix maintained 97% of its initial magnetic performance after multiple spray runs.
Abstract
As cold spray additive manufacturing matures, significant efforts are being made to develop spray conditions for more challenging materials, thereby expanding the technology’s range of applications. One main challenge while using commercially available equipment is that, even under optimized conditions, deposition efficiency remains low for some materials. Powder particles that do not adhere are wasted, which can severely affect the process economics, especially in a mass production context and/or when expensive feedstocks are used. Powder recovery and reuse is a logical solution to mitigate this problem, yet few studies evaluate its feasibility and its impact on powder characteristics and ultimately coating performance. In this work, powder recovery was investigated for two cases: a Ni powder and a NdFeB-Al powder mix, used respectively for repair applications and for the fabrication…
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Taxonomy
TopicsHigh-Temperature Coating Behaviors · Fluid Dynamics and Heat Transfer · Metal Alloys Wear and Properties