NOVEMBER 30 - DECEMBER 1, 2016Alberta Innovates – Technology Futures (AITF) | Edmonton, Alberta, Canada

NORTH AMERICANCOLD SPRAY CONFERENCE

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W W W . A S M I N T E R N A T I O N A L . O R G / C O L D S P R A Y

Final Program

Join us on April 11-12, 2017 for Thermal Spray Characterization: Materials, Coatings, and Processes, a new symposium from the ASM Thermal Spray Society (TSS). This two-day event will be focused on learning and discussing past, present and future methods of characterization of thermal spray materials, coatings and processes in order to understand the state of the industry and where it is headed.

The event will help answer these important questions:• What type of characterization methods are being implemented or emerging

to improve the reliable manufacturing of thermal spray coatings?

• What are the OEMs views of future process controls and characterization requirements and what will be expected of coating applicators and their vendors?

• What are the needs of the coating applicators in order to meet the needs of the OEMs?

• What are manufactures of powder and equipment doing to improve the cost effectiveness of characterization and quality requirements needed by coating applicators and OEMs?

If you want to discuss these questions with colleagues in the industry and hear practical case studies on the subject, you won’t want to miss this show.

Mark your calendar today!

THE FUTURE OF THERMAL SPRAY CHARACTERIZATION!

Organized by:

CO-LOCATED WITH AEROMAT THE TOP AEROSPACE MATERIALS CONFERENCE IN THE INDUSTRY

INTERESTED IN EXHIBITING / SPONSORING?Contact: Christina SandovalGlobal Exhibition Manager Phone: 440-338-5151 ext. 5625

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Day/Date Hours Location

Wednesday, November 30, 2016 07:30 – 16:30 Auditorium Foyer

Thursday, December 1, 2016 07:30 – 16:30 Auditorium Foyer

EXHIBIT DATES AND TIMESWednesday, November 30 10:00 – 16:30 Refreshment Break 10:15 – 10:30 Lunch 12:00 – 13:00 Refreshment Break 15:00 – 15:15

Thursday, December 1 10:00 – 15:30 Refreshment Break 10:15 – 10:30 Lunch 12:00 – 13:00 Refreshment Break 15:00 – 15:15

ORGANIZING COMMITTEECONFERENCE CHAIRAndré McDonald, University of Alberta

COMMITTEE MEMBERSBertrand Jodoin, University of Ottawa

Jean-Gabriel Legoux, National Research Council of Canada

Marc Levesque, Centerline (Windsor) Ltd.

Christian Moreau, Concordia University

Luc Pouliot, TECNAR

Julio Villafuerte, Centerline (Windsor) Ltd.

ABOUT THE EVENTThe ASM Thermal Spray Society and the Canadian Cold Spray Alliance have joined together to present the 2016 North American Cold Spray Conference. This biennial event is where you will learn the latest technical insights from international experts in industry, government, and academia on new technology, exciting applications, and cutting-edge research. Many of the abstracts presented during this conference will be featured in a Special Edition of the Journal of Thermal Spray Technology on Cold Spraying.

LOCATIONThe technical program and exhibits will be held at: Alberta Innovates – Technology Futures (AITF) 250 Karl Clark Road Edmonton, AB, Canada

Morning and afternoon shuttle service will be provided to AITF for guests staying at the Holiday Inn Express Edmonton South only. Guests staying at any other location should arrange for their own transportation to the conference venue.

GENERAL INFORMATIONREGISTRATION SCHEDULE

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SPECIAL EVENTSWEDNESDAY, NOVEMBER 30, 2016Young Professionals Presentation Competition14:00 – 16:30This special competition will allow undergraduate and graduate students working in the area of cold spraying the opportunity to present on their most recent research results. This element of the conference program will feature oral presentations that will be 15 minutes in duration, including time for questions and responses. The presentations will include a review by expert judges and the award of prizes to the students with the best presentations.

WEDNESDAY, NOVEMBER 30, 2016Networking Event at the University of Alberta17:30 – Shuttles Depart AITF 18:00 – 21:00 – Networking Event and ToursJoin your Cold Spray colleagues for a special networking event at the University of Alberta. Attendees will have the unique opportunity to tour the educational and research facilities at the new Donadeo Innovation Centre for Engineering, which opened in 2015. Cocktails and heavy hors d’oeuvres will be served during the event.

Note: Shuttle service will be provided from AITF to the University of Alberta. At the conclusion of the evening, the shuttle will return guests to AITF, as well as the Holiday Inn Express Edmonton South (conference headquarter hotel). Transportation to/from any other hotel is the responsibility of the attendee.

Sponsored by:

ASM Thermal Spray Society2017 Conference Calendar

April 10-11, 2017Thermal Spray Characterization: Materials, Coat-ings and Processes(co-located with AeroMat 2017)Charleston, SC USA

June 7-9, 2017International Thermal Spray ConferenceDusseldorf, Germany

September 13-14, 2017Thermal Spray of Suspensions & Solutions Sym-posium (TS4)Schenectady, NY USA

Please visit asminternational.org/conferences for additional information.

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TECHNICAL PROGRAM SCHEDULEDAY 1 – WEDNESDAY, NOVEMBER 30, 201607:15 – 08:00 SHUTTLE TO AITF (FROM HOLIDAY INN EXPRESS EDMONTON SOUTH ONLY)08:00 – 08:30 CONTINENTAL BREAKFAST

08:30 – 09:15Welcoming Remarks – Mr. Doug Puerta, Element Materials Technology and TSS President

WELCOME ADDRESS: Dr. André McDonald, University of Alberta and TSS Vice PresidentCold Spray Activities in Canada

Session 1: Science and Engineering of Powders (Session Chair: Dr. Stephen Yue)

09:15 – 09:45 Dr. Dominique Poirier, National Research Council CanadaPowder Development and Qualification for Nuclear Waste Canister Application

09:45 – 10:15 Dr. Richard Chromik, McGill UniversityNanomechanical Testing for Cold Spray—Powders, Coatings, and Third Bodies

10:15 – 10:30 REFRESHMENT BREAK WITH EXHIBITORS

Session 2: Equipment and Quality Control (Session Chair: Mr. Luc Pouliot)

10:30 – 11:00 Dr. Jianfeng Wang, SST Centerline, Ltd.Advances in the Repair of APU Generator Housings by Downstream-Injection Cold Spray

11:00 – 11:30 Mr. Sylvain Desaulniers, Polycontrols Technologies, Inc.Ultrafine Powder Feeding In Thermal Spray Application

11:30 – 12:00 Mr. Peter Richter Jr., Impact Innovations GmbHAdvanced High-Pressure Cold Spray—Equipment, Coatings, and Selected Applications

12:00 – 13:00 LUNCH WITH EXHIBITORS Sponsored by Polycontrols Technologies Inc.

Session 3: Fundamentals: Physics, Science, Modelling, and Characterization (Session Chair: Dr. Tim Eden)

13:00 – 13:30 Dr. Bertrand Jodoin, University of OttawaCold Spray Fundamentals: From Surface Preparation to Particle Interactions

13:30 – 14:00 Mr. Victor Champagne, US Army Research LaboratoryAdvancements in Cold Spray Aluminum Alloys

YOUNG PROFESSIONALS PRESENTATIONS AND COMPETITION (Session Chair: Dr. Bertrand Jodoin)

14:00 – 14:15 Muhammad Faizan-Ur-Rab, Swinburne University of TechnologyCold Spray 3D Multicomponent Model Validation with PIV and Particle Location

14:15 – 14:30 Hanqing Che, McGill UniversityCold spray on Carbon Fibre Reinforced Polymers for Lightning Strike Protection

14:30 – 14:45 Ozan Ozdemir, South Dakota School of Mines & TechnologyBetter Predictions Using 3D CFD to Inform Cold Spray Process Development

14:45 – 15:00 Klara Petrackova, Polytechnic University of MilanFatigue Life of Cold-Sprayed Aluminium Alloy Coating for Repair Application

15:00 – 15:15 REFRESHMENT BREAK WITH EXHIBITORS

15:15 – 15:30Yinyin Zhang, McGill UniversityMicrostructural Evolution and Nanohardness of Cold-Sprayed Cu during Annealing—Electron Backscattered Diffraction and Nanoindentation

15:30 – 15:45Amirhossein Mahdavi, University of AlbertaSemi-Empirical Analytical Determination of the Heat Transfer Coefficient of the Impinging Air Jet upon a Flat Substrate during Cold Spraying

15:45 – 16:00 Xin Chu, McGill UniversityCharacterization and Deposition Behaviors of Cold-Sprayed Mixed 316L/Fe Coatings

16:00 – 16:15 Sima Alidokht, McGill UniversityCold Spray Deposition of Ni-WC Composite Coatings

16:15 – 16:30 Roy Lee, University of AlbertaThe Effect of Fracture Toughness on the Deposition Efficiency of Ceramic Particles in Cold Spray

NETWORKING EVENT AT THE UNIVERSITY OF ALBERTAShuttle Departs AITF (17:30)

Cocktails and Tours (18:00–19:30)Informal Networking Dinner and Award Announcements (19:30–21:00)

Sponsored by TECNAR

NoteAt the end of the evening, shuttle will return guests to AITF and

those staying at the Holiday Inn Express Edmonton South

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DAY 2 – THURSDAY, DECEMBER 1, 2016 07:15 – 08:00 SHUTTLE TO AITF (FROM HOLIDAY INN EXPRESS EDMONTON SOUTH ONLY)

08:00 – 08:30 CONTINENTAL BREAKFAST

08:30 – 09:15 KEYNOTE SPEAKER: Dr. Daniel Greving, Honeywell Inc.How Cold Spray is Changing Aerospace Aftermarket Repair Strategies

Session 4: Fundamentals: Physics, Science, Modelling, and Characterization(Session Chair: Dr. Jean Gabriel Legoux)

09:15 – 09:45 Dr. Tim Eden, Pennsylvania State UniversityMicroporous Coatings for Enhanced Heat Transfer and Steam Impulse Tube Repair

09:45 – 10:15Dr. Stephen Yue, McGill UniversityUnderstanding the Deposition Efficiency Characteristics of 316L/Fe Mixed Powders Using Single Particle Impact Tests

10:15 – 10:30 REFRESHMENT BREAK WITH EXHIBITORS

Session 5: Applications—Case Studies, Cost Analysis, and Optimization (Session Chair: Dr. Richard Chromik)

10:30 – 11:00 Dr. Heli Koivuluoto, Tampere University of TechnologyOverview of Laser-Assisted Cold-Sprayed Metallic Coatings

11:00 – 11:30 Dr. Christian Widener, South Dakota School of MinesRepair and Applications Development for High-Pressure Cold Spray

11:30 – 12:00 Dr. Gary Fisher, InnoTech AlbertaThe Development and Integration of New Technologies for the Albertan Thermal Spray Industry

12:00 – 13:00 LUNCH WITH EXHIBITORS Sponsored by Polycontrols Technologies Inc.

Session 6: Additive Manufacturing (Session Chair: Dr. Éric Irissou)

13:00 – 13:30 Dr. Sara Bagherifard, Polytechnic University of MilanPotential of Cold Spray Deposition Technique for Fabrication of Freestanding Inconel Components

13:30 – 14:00 Dr. Phuong Vo, National Research Council CanadaToolpath and Build-up Strategies for Cold Spray Additive Manufacturing

14:00 – 14:30 Dr. Stefan Gulizia, Commonwealth Scientific & Industrial Research OrganizationCold Spray Additive Manufacturing—From the Laboratory to the Market

14:30 – 15:00 Dr. Jean-Michel Lamarre, National Research Council CanadaPermanent Magnet produced by Cold Spray for Automotive Electric Engines

15:00 – 15:15 REFRESHMENT BREAK: Visit Show Floor & Exhibitors

Session 7: Applications—Case Studies, Cost Analysis, and Optimization (Session Chair: Dr. André McDonald)

15:15 – 15:45 Dr. Harminder Singh, Guru Nanak Dev UniversityFabrication of Cold Sprayed Coating for Waste Incinerator Conditions

15:45 – 16:15 Dr. Jean-Gabriel Legoux, National Research Council CanadaProcess Development for Adhesion of Thick Copper Coatings to Used (Nuclear) Fuel Containers

CLOSING REMARKS—Dr. Jean-Gabriel Legoux, Guest Editor, Special Edition on Cold Spraying, Journal of Thermal Spray Technology

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ABSTRACTS (alphabetical by abstract title)

ADVANCED HIGH-PRESSURE COLD SPRAY—EQUIPMENT, COATINGS AND SELECTED APPLICATIONSPeter Richter Jr., Leo Holzgassner, and Jan Kondas

Impact Innovations GmbH, Bürgermeister-Steinberger-Ring 1, 84431 Haun/Rattenkirchen, Germany

High-pressure cold spray is an emerging technology where emphasis for equipment design and capabili-ties is critical for the evolution to developing diverse applications in industries around the globe. Impact Innovations, a leading manufacturer of high pressure cold spray equipment, is continuously developing pro-cess material parameters, it´s components and special tools to meet unique application development leading to successful and notable applications along with high production equipment durability and consistency. Es-sential parameter and equipment capabilities such as process gas pressures and gas temperatures need to be continually developed for critical particle impact velocities to ensure spray-ability of a wide range of materials. But not only physical process parameters are needed to achieve innovative results; software and hardware development are under on-going develop-ment to reach new limits.

This presentation will give an overview of the most common and “state-of-the-art” cold spray equipment, newly developed coatings and some selected applica-tions out of various industrial fields (e.g., additive ma-nufacturing, repair applications and CerMet coatings).

ADVANCEMENTS IN COLD SPRAY ALUMINUM ALLOYSVictor K. Champagne

U.S. Army Research Laboratory, Aberdeen, MD, USA

This paper will discuss the advancement of cold spray aluminum aerospace alloys by the U.S. Army Research Laboratory in conjunction with a research team that includes industry and academia and the efforts un-derway to expand their use for the repair of structural components and additive manufacturing. It is well un-derstood that the cold spray process has been qualified for use in the aerospace industry as a repair technol-ogy for the restoration of aerospace materials, includ-ing; aluminum and magnesium alloys. The use of cold spray has been primarily limited to dimensional res-toration of corroded, worn or damaged parts and for ‘nonstructural’ applications. The disadvantage of the use of cold spray has been primarily due to low ductil-

ity in the as-sprayed condition and limitations in bond strength on hardened materials, such as steel but ad-vancements in novel powder processing has resulted in unprecedented increases in strength, ductility and adhesion. Data will be presented regarding the devel-opment of aluminum aerospace alloys with increased strength and ductility. Tensile strengths of cold spray aluminum alloys exceeding 172 MPa (25 ksi) with corre-sponding shear strengths greater than 138 MPa (20 ksi) have been achieved when deposited onto magnesium and aluminum alloy substrates, as well as hardened steel (HRC 50). Strength levels of 414 MPa (60 ksi) ulti-mate tensile strength with a corresponding ductility of over 15% elongation have been reported for bulk cold spray 5056 Al alloys. An overview of the state-of-the-art of cold spray aluminum aerospace alloys will be dis-cussed and their current use. Comparisons of materials properties will be made as well as applications in the aerospace industry.

ADVANCES IN THE REPAIR OF APU GENERATOR HOUSINGS BY DOWNSTREAM-INJECTION COLD SPRAYJulio Villafuerte, Ph.D., P.Eng. Jianfeng Wang, Ph.D., Wally Birtch, P.Eng.

CenterLine (Windsor) Ltd.

Cold spray technology emerged as a practical technol-ogy in the 1980’s from the Russian Academy of Sciences in Novosibirsk. Thirty five years later, the commercial implementation of this technology continues to grow in the aerospace industry for applications such as di-mensional restoration of high-value aluminum and magnesium housings. One attribute of this technology is its ability to create well-bonded, low porosity, oxide-free coatings in the solid state and at low temperatures which results in minimum or no distortion when uti-lized to restore tight tolerance aircraft components. This presentation will focus on the new advances on equipment, cold-sprayable materials, and methods to repair APU generator and gearbox housings which are used in a number of commercial aircraft including Boe-ing 737NG, 747, 777; Airbus A320, A330, and A340. These components are routinely restored to OEM specifica-tions by a number of qualified cold-spray repair depots including Honeywell, LJ Walch, Ohlinger Industries, Tri-umph Accessory and Accuwright, that have been com-mercially using cold spray for the last 5-10 years. This practice has saved the aerospace industry millions of dollars while creating a new world of opportunities.

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COLD SPRAY ADDITIVE MANUFACTURING—FROM THE LABORATORY TO THE MARKETStefan Gulizia, Peter King, S. Zahiri, A. Urban, M. Styles

CSIRO Manufacturing

Cold spray additive manufacturing has emerged as a key competitor for existing technologies such as cast-ing, ingot metallurgy and powder metallurgy. It offers a combination low-cost manufacturing with enhanced properties and performance that’s particularly well-suited for manufacturing component preforms and mill products directly from titanium powder in a single step. The property benefits arise from solid state deposition, which promotes microstructural refinement and elimi-nates macrosegregation. When used in conjunction with novel low-cost titanium metal powder production, cold spray additive manufacturing becomes a transfor-mational manufacturing technology challenging tradi-tional titanium manufacturing routes. This presenta-tion will describe CSIRO patented cold spray additive manufacturing technologies to manufacture continu-ous pipe, billets and preforms, all these directly from low-cost titanium binder-less powder feedstocks. The characterization of the microstructure and mechanical properties produced with different powder feedstocks will be described, together with results of a holistic CFD model used to predict temperature, velocity, deposi-tion efficiency and distribution of particles exiting the jet. The strengths and opportunities of cold spray addi-tive manufacturing technology and its potential impact to the emerging additive manufacturing industry in the aerospace, defense and medical industries will also be presented and examined.

COLD SPRAY FUNDAMENTALS: FROM SURFACE PREPARATION TO PARTICLE INTERACTIONSBertrand Jodoin

University of Ottawa, Ottawa, Ontario, Canada

Surface preparation in cold spray has received little at-tention so far. While a few studies have initiated some work in the area, few studies have explored specifically the effect of surface preparation on adhesion mecha-nisms. Furthermore, while the effect of using a second harder phase (most often ceramic) on cold spray coa-ting microstructure and mechanical properties have been exposed in the early days, a thorough study to un-derstand the fundamental phenomena in cause is still lacking. The presentation will address those two points to give more insight of the complex physics involved in cold spray.

FABRICATION OF COLD SPRAYED COATING FOR WASTE INCINERATOR CONDITIONS Harminder Singh

Guru Nanak Dev University, Regional Campus

The working environment of waste incinerators is high-ly corrosive at high temperature. This is mainly due to the presence of chlorine-based molten salt deposits on the plant components. Chlorine is highly corrosive in nature and its presence even in a very small amount (0.1%) in molten deposits results in active-oxidation mechanism failure of the metals or even superalloys. Incinerators are used as waste management plants; therefore, it is not possible to control the waste compo-sition which is used as fuel in these plants. To mitigate this corrosive problem, there is need to develop highly dense corrosion resistant surface coatings. In this pres-ent study, relatively new cold spray technique is used to develop Ni-Cr-based corrosive resistant coating on superalloy surface. The microstructure of cold sprayed surface is tested by various techniques and coated sur-face is tested in waste incinerator environment at aver-age temperature of 900ᵒC (1652ᵒF). It is found that the newly developed coated surface is dense (porosity less than 1%), hard and smooth. The dense coating is able to restrict the transport of chlorine present in the molten deposits towards the superalloy substrate, there is no indication of active oxidation mechanism and coating remains adhered with the base alloy during corrosion tests. The corrosion rate of coated superalloy is found to be less as compared to bare superalloy. These results have indicated that the microstructure of surface coat-ing developed by cold spray process is suitable for cor-rosive applications at high temperature conditions.

MICROPOROUS COATINGS FOR ENHANCED HEAT TRANSFER AND STEAM IMPULSE TUBE REPAIR Timothy J. Eden1,3, Jiří Žďárek2, Al Segall3 and Bill Cheung4

1 Applied Research Laboratory, The Pennsylvania State University

2UJV Rez

3Engineering Science and Mechanics, The Pennsylvania State University

4Bill Cheung, Mechanical and Nuclear Engineering, The Pennsylvania State University

During a severe accident, the reactor core can melt down allowing the molten corium to settle in the lower head of the reactor pressure vessel (RPV). The containment area where the RPV is located is flooded with water to remove enough heat to prevent the corium from melting through the wall of the RPV. This is also known as in-ve-

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TJGN1600

Journal of Thermal Spray Technology®

From the scientific to the practical—stay on top of advances in this fast-growing coating technology

ASM Journals are the highly specialized way to further your materials science knowledge on the latest research, applications, and problem solving techniques from a reliable, trusted source. Stay current. Stay ahead.

• Critically peer-reviewed scientific papers and engineering articles combine the best of new research with the latest applications and problem solving

• Covers all fundamental and practical aspects of thermal spray science, including processes, feedstock manufacture, and testing and characterization

• Includes technical note case studies from real-time applications and in-depth topical reviews

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ssel retention (IVR). The high temperature of downward facing surface of the RPV causes the water to boil which removes heat from the RPV. The process depends on the critical heat flux (CHF) limit of the downward facing boiling process. The addition of a microporous coating with interconnected porosity can greatly enhance the boiling process and increase the heat flux from the RPV to the cooling water. In this effort, stainless steel coa-tings with interconnected microporosity were produced using the cold spray process and evaluated on subscale test articles. Downward facing boiling tests were condu-cted on two stainless steel hemispheres, one with the porous coating and one without surface enhancement. The outer diameter of hemispheres was approximately 1016 mm (40 in.). Each hemisphere was instrumented with thermocouples, heated to 350°C (662oF) and sub-merged in saturated water. The temperatures at differ-ent locations on the hemispheres were recorded and used to calculate the heat flux. Results showed that the microporous coatings greatly enhanced the boiling heat transfer process. Thermal cycling and high-heat flux, high-velocity flow experiments on flat, subscale test articles demonstrated the viability of the microporous coatings. Work is in progress to develop the process for applying microporous coatings on bottom head of full-scale RPVs. In addition, the cold spray process is being used to develop repairs for damaged impulse tubes used in nuclear power plants. A through wall crack in an im-pulse tube was repaired and is in the process of being evaluated. Initial testing at elevated temperature and full working pressure have successfully been conducted.

NANOMECHANICAL TESTING FOR COLD SPRAY—POWDERS, COATINGS AND THIRD BODIESRichard R. Chromik, YinYin Zhang, Sima Alidokht, Ata Saeed and David Chern

McGill University, Department of Mining and Materials Engineering

At all stages of a cold sprayed coating’s lifetime, there are instances of inhomogeneous microstructures. Feed-stock powders often have significant variability in their microstructure, even within a single particle. As-sprayed coatings have regions that retain powder microstructure and other regions with recrystallized grains. In-service, coatings subjected to wear have the formation of me-chanically modified layers (MML) near surface that are often referred to as third bodies. A powerful technique to measure the mechanical properties associated with these various microstructures is nanoindentation. Ide-ally, nanoindentation can provide data required to gen-erate computational models of cold spray that account for these microstructural variations.

In this work, we report on nanoindentation measure-ments of feedstock powders, cold spray coatings and third bodies produced from the coatings after wear testing. For powder, special care was taken to produce reliable test conditions and analysis strategies for mi-

cron sized powders embedded in a soft matrix. For cold spray coatings, mapping of mechanical properties are presented and tied to various microstructural features observed by electron backscatter diffraction (EBSD) and electron channeling contrast imaging (ECCI). And for third bodies, mechanical property changes are cor-related to the microstructural modifications induced by wear. Materials systems reported on include Al-Al2O3, Cu-MoS2 and Ni-WC coatings.

OVERVIEW OF LASER-ASSISTED COLD-SPRAYED METALLIC COATINGSHeli Koivuluoto

Tampere University of Technology, Department of Ma-terials Science

In the cold spray process, solid particles impact with high-kinetic energy, deform plastically and form a coating. Basically, this enables the formation of pure and dense coating structures. Even more, coating performance and deposition efficiency can be improved by assisting the process with a laser. Laser-assisted cold spraying (LACS) has shown its potential to improve coating properties compared with traditional cold spraying. In this study, coating quality improvement was gained by using a co-axial laser spray (COLA) process which offers a new, cost-effective laser-assisted cold spray technique, for high-quality deposition and repair. In the COLA process, the sprayed surface is laser-heated while particles hit the surface. This assists the better bonding between par-ticles and substrate and leads to the formation of tight coating structures. This study focuses on the evaluation of the microstructural characteristics and mechanical properties (e.g., hardness and bond strength) of LACS metallic coatings. For example, denser Ni20Cr coatings with higher deposition efficiency have been produced by using LACS process compared to CS process. Addition-ally, laser-assistance can behave as an online heat-treat-ment by recovering the structures during the spraying. This behavior was perceived with LACS Ni and Ni20Cu coatings which showed lower hardness and recrystal-lized structures compared to the corresponding coatings without laser-assistance. Furthermore, in the case of Al coatings, LACS process increased the adhesion strength of the LACS Al coatings on Al and steel substrates. In con-clusion, laser-assisted cold spraying is a relatively new hybrid process which has shown its potential for high-quality metallic coating production.

PERMANENT MAGNET PRODUCED BY COLD SPRAY FOR AUTOMOTIVE ELECTRIC ENGINESJean-Michel Lamarre, Fabrice Bernier

National Research Council Canada

Environmental targets imposed in the last few years in several countries led the automotive industry to shift from fossil fuel motors to alternative hybrid and electri-

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cal technologies. The spread of these new hybrid and electrical powered vehicles is strongly dependant on their cost. There is thus an important need to identify technologies to reduce the cost of electrical engines. For permanent magnet electric motors, the cost of the mag-nets can represent up to 50% of the total motor cost. This derives not only from the high cost of the rare earth materials necessary to fabricate permanent magnets but also from the required assembly steps. Current tech-niques used for the assembly of permanent magnets in motors such as adhesives, slots or screws are complex, labour intensive and offer very little flexibility for ad-vanced motor design strategies. In this work, we will de-scribe the use of cold spray additive manufacturing for the low-cost direct shaping of permanent magnets on electric motor parts without the need for additional as-sembly steps. The permanent magnets were fabricated from a metal-NdFeB powder mixture featuring high-raw theoretical remanence and coercivity. The role of the powder composition, size distribution and morphol-ogy on the spray efficiency, the magnetic properties, the coating diffusivity and the coating adhesion will be dis-cussed. The effect of the spray parameters such as the gas temperature on the coating magnetic phase fraction, the remanence and the coercivity will also be discussed. The use of robot toolpath programming necessary to spray on motor parts will be illustrated by different ex-amples of complex shape prototypes. A simple analysis of cold spray magnet production cost will be presented. The obtained magnetic properties results demonstrate the feasibility of using cold spray additive manufactur-ing as an effective technology to fabricate motor parts without additional assembly steps.

POTENTIAL OF COLD SPRAY DEPOSITION TECHNIQUE FOR FABRICATION OF FREESTANDING INCONEL COMPONENTSSara Bagherifard1, Mehdi Hadi1, Gianluca Roscioli1, Maria Vittoria Zuccoli1, Ján Kondás2, Mario Guagliano1

1Politecnico di Milano, Department of Mechanical Engi-neering, Via La Masa, 1, 20156, Milan, Italy2Impact Innovations GmbH, Bürgermeister-Steinberg-er-Ring 1, 84431 Haun/Rattenkirchen, Germany

Additive manufacturing techniques are becoming an in-tegral part of the industrial production chains across all manufacturing industries. Offering the possibility of ob-taining almost zero-porosity build-ups with no theoreti-cal limit to the thickness, cold spray has high potential to be used as an additive manufacturing technique for fab-rication of freestanding components. Furthermore, cold spray can eliminate particle melting, evaporation and crystallization due to the cold nature of the process. This implies avoidance of unwanted oxidation, formation of undesirable phases and thermally induced tensile resid-ual stresses, making this method an apt one for working with oxygen and temperature sensitive materials. Bear-ing in mind all these positive points, cold spray deposi-tion method is finding its path towards fabrication of freeform components since it can address the common challenges of powder-bed additive manufacturing tech-niques including major size constraints, deposition rate limitations and high processing temperature.

VRC Metal Systems is an advanced materials process technology manufacturer specializing in turnkey systems for cold spray and additive manufacturing. These technologies have applications in aerospace, defense, heavy industrial, oil & gas, biomedical, electronics, consumer products, and repair and refurbishment of high value components.

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Herein, we prepared Nickel-based alloy Inconel 718 samples with cold spray technique and compared their mechanical and structural characteristics with similar samples fabricated through the most diffused additive manufacturing technology, which is selective laser melt-ing (SLM) method. Inconel 718 is a super alloy commonly used in extreme environments subjected to pressure and heat, and is widely used for turbines and heat exchang-ers in energy and aerospace industry. Different heat treatment cycles have been applied to the cold sprayed samples in order to enhance their mechanical character-istics. The samples fabricated using both cold spray and SLM methods have been characterized in terms of me-chanical strength and structural integrity, microstructur-al and porosity characteristics, Vickers microhardness and residual stresses distribution. The results indicate great potential of cold spray technique for fabrication of high quality freestanding components. The obtained data confirm that this technique can be used as a com-plementary additive manufacturing method devoted to applications where higher deposition rate, larger final size and lower fabrication temperatures are desired.

POWDER DEVELOPMENT AND QUALIFICATION FOR NUCLEAR WASTE CANISTER APPLICATIONDominique Poirier1, Jean-Gabriel Legoux1, Phuong Vo1, Jason D. Giallonardo2, Peter G. Keech2

1National Research Council, Boucherville, Quebec, Canada2Nuclear Waste Management Organization, Toronto, Ontario, Canada

Over several years, the cold spray process has advanced through a number of developmental stages, from initial concept to optimization, maximization of efficiency, reliability and cost minimization. Now that cold spray physics and technical aspects are better grasped, there is a rising interest to understand the effects of powder characteristics on powder cold sprayability and coating quality. Successful coatings are achieved from powders controlled in terms of shape, size and metallurgy.

This paper presents the development work undertaken to tailor copper powder for the specific application of a corrosion barrier coating to Used nuclear Fuel Contain-ers (UFCs). Indeed, the current approach for nuclear fuel disposal in Canada is to store the bundles in specially designed containers that will be emplaced in the rock of a suitable geological formation at a minimum of 500 m (547 yd) of depth for an intended lifespan of more than 100,000 years (i.e., indefinite storage). The Canadian UFC reference design consists of a steel structural core strong enough to withstand geological pressures, including glaciations scenarios, and an outer copper coating for corrosion resistance. Copper cold spray is a particular-ly promising technique for applying the coating at the weld closure zone of the UFC. This paper outlines how the powder features were tailored to achieve the coating application requirements in terms of adhesion, density,

ductility and composition. Following screening trials, the most promising powders were selected to perform the scale-up work. The use of several lots in a production-type environment allowed further powder specification refinement to ensure cold sprayability and to achieve coating requirements. From this context, issues related to lot variability and lack of adequate powder character-ization protocols for quality control are also discussed.

PROCESS DEVELOPMENT FOR ADHESION OF THICK COPPER COATINGS TO USED (NUCLEAR) FUEL CONTAINERSJean-Gabriel Legoux1, Dominique Poirier1, Jason Gial-lonardo2, Phuong Vo1, and Sylvain Bournival1

1National Research Council of Canada, Boucherville, Quebec, Canada2Nuclear Waste Management Organization, Toronto, Ontario, Canada

Over the last several years, the National Research Council (NRC) has developed a cold sprayed thick cop-per coating for the Nuclear Waste Management Orga-nization (NWMO) intended to act as a corrosion barrier for used fuel containers (UFC). The UFC was designed for the storage of Canada’s spent nuclear fuel in a deep geological repository (DGR). It consists of a carbon steel structural core coated with a copper. Using a conserva-tive approach, it was determined that a copper coating thickness of 3 mm (0.12 in.) is required for corrosion protection under DGR conditions. Based on prelimi-nary analyses, the key mechanical requirements for the copper coating are sufficient adhesion strength to the steel substrate and high ductility. This paper will pres-ent the latest advances in copper coating development activities and their application to UFC’s.

Copper is often considered as one of the most adapt-able materials for the cold spray process; however, this statement can be misleading where the deposition of thick copper coating on a large steel structure is re-quired. Experimental results on key parameters affect-ing adhesion will be presented and discussed with em-phasis for the specific application of copper cold spray to large parts. Particle velocities have shown to play a major role in the development of an adherent coating. Up to now, sufficient adhesion of copper over steel has only been obtained while using helium as the propel-lant gas since particle velocities above 800 m/s can be achieved. Surface conditions such as roughness and temperature have also shown a great influence on the coating adhesion strength. Additionally, the coating build-up rate and its relation to part movement were found to play a major role on the adhesion strength. Finally, adhesion is also influenced by the surface tem-perature of the part being coated. To demonstrate this, results of thermal modelling will be described and the development of a representative sample holder based on those results will be presented.

13

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REPAIR AND APPLICATIONS DEVELOPMENT FOR HIGH PRESSURE COLD SPRAYChristian A. Widener1,2, Michael Carter1, Todd Curtis1, Robert Hrabe2

1South Dakota School of Mines and Technology2VRC Metal Systems

In recent years, incredible advancements have been made in terms of the properties achievable with cold spray using high pressure. This has expanded the ar-eas of potential usefulness of the technology for struc-tural repairs and other applications, including additive manufacturing. These advancements have come about because of improvements in equipment design and ca-pabilities as well as the advancement of our fundamen-tal understanding of the cold spray process. As a result, some very important and valuable applications have been developed using cold spray, with many more in the works or yet to be explored. In order to properly ap-ply the technology; however, a thorough understanding of the process, the component itself, and materials sci-ence in general is needed to successfully implement the technology. The authors have been working to develop high pressure cold spray applications for industry and the repair of critical components for the Department of Defense to extend the life and reduce maintenance costs for legacy weapon systems. These efforts have been de-

veloping best practices for the engineering assessments needed to properly apply cold spray, as well as identi-fied lessons learned and other information that needs to be disseminated into the broader community in order to bolster the adoption of this important technology. These lessons learned and best practices also extend to quali-fication efforts which are needed before this technology can be fully adopted. For example, in order to incorpo-rate any new technology into a new market segment, you must understand the current applicable standards, governing bodies, and approval authorities. The process must also be a controlled and bounded process, with an understanding of the acceptable variation and result-ing property variations. Current standards must then be modified or supplemented with new standards to include cold spray. In order to accomplish these goals, stakeholder involvement is required and at least one market champion to push adoption. Next, when choos-ing initial target applications, there needs to be a consid-eration of risk vs. benefit and a staged implementation plan where confidence in the technology and success cases can be built up. Finally, funding must be secured for the qualification effort, whether through private in-vestment or government funding, based on a compelling return on investment because of significant advantages that cold spray offers to the new market segment over competing technologies. The adoption of any new tech-nology can be challenging, but the recent advancements in high pressure cold spray are showing the potential to provide significant benefits across a wide range of mar-ket sectors.

14

THE DEVELOPMENT AND INTEGRATION OF NEW TECHNOLOGIES FOR THE ALBERTAN THERMAL SPRAY INDUSTRYGary Fisher, Ph.D., PEng and Tonya Wolfe, Ph.D., PEng

InnoTech Alberta

The resource industries in Alberta place high demands on the requirements of protective coatings. The wear and corrosion issues prevalent across these industries require highly durable, reliable materials and the appli-cation of coatings across a wide range of component geometries. The coatings industry within the Province, whilst accepting of new technologies, may not have the time or resources to fully investigate the potential of new processes and equipment. The Alberta Manu-facturing and Fabrication Innovation (AMFI) program at Alberta Innovates – Technology Futures (AITF) is a mechanism whereby new deposition technologies and coating materials can be independently reviewed and assessed for Albertan coatings industry. The AMFI program raises awareness of the newest and most advanced coating solutions available and provides Al-bertan companies with the necessary resources to ef-fectively evaluate solutions for specific needs and effi-ciently integrate those solutions into their operations. This presentation will explain how the AMFI program works closely with equipment and materials manufac-turers to transfer expertise to the Albertan coating sec-tor. Examples of previous work will include the iden-tification of spraying equipment for internal diameters and the process developments for local spray shops.

The Surface Engineering group at AITF is also actively involved in the design of new composites for protec-tive applications, introducing the products to indus-try through programs such as AMFI. This includes, in partnership with the University of Alberta, the design of cold spray deposited coatings. Work on a cold spray-deposited composite for antibacterial protection in the Food preparation industry will be presented, showing how the coating was design to resist both two-body abrasion and provide effective protection against bac-terial pathogens.

TOOLPATH AND BUILD-UP STRATEGIES FOR COLD SPRAY ADDITIVE MANUFACTURINGPhuong Vo, Manuel Martin

National Research Council Canada

Cold spay processing features several benefits (e.g., low process temperature, rapid build rates, multi-material deposition, etc.) that are attractive for additive manu-facturing (AM) of 3D metal parts. In order to fully real-

ize the potential of cold spray AM; however, it is nec-essary to factor in technology-specific considerations throughout the entire AM process as some aspects of cold spray differ markedly from other AM technolo-gies such as powder-bed. One essential stage in this process is the conversion of an original CAD drawing into a layer-by-layer geometry (i.e., slicing the part) from which a robot toolpath can be subsequently gen-erated to move the spray gun, or alternatively, a part when the gun position is fixed. The toolpath genera-tion and programming required to build 3D structures can introduce an added layer of complexity versus that required for other cold spray applications such as coatings, which can often be performed manually by a skilled operator. Moreover, effective toolpath planning employs a variety of strategies to improve the fidelity of as-sprayed geometries and move towards the goal of near net shape parts. This presentation presents recent advances for the additive manufacturing of 3D features using cold spray through the use of industrial offline ro-bot programming via commercially available software. Examples of fine features and near net shape parts are given to illustrate toolpath and build-up strategies.

ULTRAFINE POWDER FEEDING IN THERMAL SPRAY APPLICATIONSylvain Desaulniers, Eng

Polycontrols Inc.

The cold spray process as well as thermal spray pro-cess (HVOF, plasma-spray) require increasing use of fine powders. Existing conventional volumetric pow-der feeders are ill-suited for this purpose and have limitations in terms of operating pressure and clogging problem.

This paper presents a novel and autonomous powder feeder operating on the principle of a fluidized bed in order to allow a continuous and uniform feeding of sub-micron powders that were not usually feedable with conventional volumetric/wheel type powder feeders. Primarily designed to produce cold-sprayed coatings, this feeder can also be used in high velocity oxy-fuel (HVOF) spray processes and plasma spray applications to significantly increase productivity by direct injection of submicron particles without requiring suspensions.

This paper presents coating micrographs of copper, nickel, zinc, aluminium, aluminium alloys and WC-Co powders with median particle size from 6 to 55 µm (0.0002 to 0.002 in.) produced via cold spraying. This paper also details the coating micrographs of suspen-sion plasma spray (SPS)-like ZrO2-Y2O3 (YSZ) coatings engineered to be employed as thermal barrier coatings (TBCs) in turbines obtained with commercial plasma spray system without the need for suspensions. A brief overview of thermal spray and cold spray applications of polycontrols will also be addressed.

15

UNDERSTANDING THE DEPOSITION EFFICIENCY CHARACTERISTICS OF 316L/FE MIXED POWDERS USING SINGLE PARTICLE IMPACT TESTSXin Chu1, Phuong Vo2, and Stephen Yue1

1Deptartment of Mining and Materials Engineering McGill University, Montreal, Quebec, Canada

2National Research Council Canada Boucherville, Quebec, Canada

Cold spray of mixed powders (metal-ceramic and met-al-metal) can offer significant benefits in improving the cold sprayability of the component powder (i.e. increase deposition efficiency and decrease porosity). However, there is still a lack of knowledge in the mech-anisms behind those improvements, especially in the case of metal-metal mixtures. This paper describes a preliminary approach to understand the deposition ef-ficiency (DE) characteristics of 316L/Fe mixed powders using single particle impact tests.

316L stainless steel powder is reported to have a bet-ter DE than commercially pure Fe under the same cold spray condition. While for 316L/Fe mixed powders, the DE increases with increasing Fe content, and high Fe content mixtures (i.e. 90wt.%Fe+10wt.%316L) even have superior DE compared to the 316L. Hence, the simple approach to predict the behavior of a mixture,

i.e., the rule of mixtures (DE=DE1×f1+DE2×f2, where fi is the corresponding weight fraction of component i), is not applicable in explaining such DE characteristics.

To help explain the DE characteristics, the different par-ticle-substrate impact scenarios during 316L/Fe mixed powders deposition were considered in this work. Sin-gle particle impact tests, generated by very low feed rate spraying of powder onto the polished coating as the substrate, were used to obtain those impact sce-narios. Four impact scenarios: 316L particle on 316L substrate, 316L particle on Fe substrate, Fe particle on 316L substrate and Fe particle on Fe substrate, were performed to represent the 316L/Fe mixed powders deposition process. As well, two additional impact sce-narios, 316L particle on 80Fe substrate and Fe particle on 80Fe substrate, were performed to investigate the effect of metal-metal substrates.

The bond ratio (BR), defined as ratio of the number of bonded particles (deposits) to the total impinged par-ticles (deposits+craters), was calculated for each im-pact scenario and a method was introduced to corre-late BR with DE. It was found that for single component and low Fe content powders, good correlations could be seen; while the correlations started to deviate in the mixed powders when the Fe content was above 20 wt%. Those deviations, together with characterization results of the cold sprayed coatings, reveal the vari-ous deposition mechanisms which could contribute to the DE characteristics in cold spraying 316L/Fe mixed powders.

CenterLine (Windsor) LimitedSupersonic Spray Technologies Division655 Morton Dr. Windsor, Ont N9J 3T9Tel: 519-734-8464 Email: info@cntrline.comwww.supersonicspray.com

We offer complete job shop services.Our factory direct service can repair, restore, refinish or recoat your component parts. Send us your sample parts for testing.

• solid-state surface engineering

• corrosion protection• transition coatings• conductive coatings• heated glass• surface restoration

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17EXHIBIT DATES AND TIMESWednesday, November 30 10:00 – 16:30 Refreshment Break 10:15 – 10:30 Lunch 12:00 – 13:00 Refreshment Break 15:00 – 15:15

Thursday, December 1 10:00 – 15:30 Refreshment Break 10:15 – 10:30 Lunch 12:00 – 13:00 Refreshment Break 15:00 – 15:15

SHOW DIRECTORY

We appreciate and acknowledge the following:

North American Cold Spray ConferenceNovember 30 – December 1, 2016

Alberta Innovates –Technology Futures (AITF)

CORPORATE SPONSORS

CORPORATE SUPPORTERS®

(WINDSOR) LIMITED

18

EXHIBITOR LIST

1. Impact Innovations2. Plasma Giken3. VRC Metal Systems

4. CenterLine (Windsor) Ltd, Supersonic Spray Technology Div.5. TECNAR6. Oseir Ltd

Tabletop # Exhibitor Tabletop # Exhibitor

The NACS Exposition designations are: Green listing indicates Sponsor, Blue listing indicates Supporters.

COMPANY DESCRIPTIONSCenterLine (Windsor) Ltd, Supersonic Spray Technology Div.

Tabletop #4 CenterLine’s Supersonic Spray Technologies Division (SST™) manufactures cold gas dynamic spray (Cold Spray) metal coating systems and supplies to protect, repair, restore, and refinish manufactured products. SST also provides a wide range of process development assistance to identify commercially viable applications for Cold Spray technology. www.supersonicspray.com

Impact InnovationsTabletop #1 Impact Innovations Cold Gas Spray Systems delivers performance pressures up to 50 bar and temperatures up to 800°C to 1100°C. ASB Industries is the North American representative for equipment sales and technical support services. Mr. Peter Richter, Mr. Leo Holzgassner and Mr. Charles Kay will be available to discuss your interests.www.asbindustries.com/cold-gas-spray-system-511

Oseir LtdTabletop #6 Oseir Ltd. has been specializing since 1999 in particle diagnostics using custom SprayWatch cameras and HiWatch camera&laser units and proprietary image processing software to extract any significant data in all thermal spray processes as well as other processes where solid particles, liquid droplets and/or bubbles are present.www.oseir.com

Supporter

Plasma GikenTabletop #2 Plasma Giken established in 1980 offers a variety of advanced cold spray systems, metal surface modification and machining, as well as designing production lines and sales of its machinery and equipment. Headquartered in Japan, Plasma Giken has always been one of the pioneers in the development of cold spraying technology.www.plasma.co.jp

TECNAR

Tabletop #5 TECNAR is the world leader in the field of advanced sensors for thermal & cold spray processes. Our portfolio covers all the range of applications from fundamental R&D to shop floor monitoring. Our flagship sensors are the DPV & Accuraspray. Please visit www.tecnar.com or email thermalspray.Sales@tecnar.com for more information.Tecnar.com

VRC Metal Systems LLC

Tabletop #3 VRC Metal Systems is an advanced materials process technology manufacturer specializing in turnkey systems for cold spray and additive manufacturing. These technologies have applications in aerospace, defense, heavy industrial, oil & gas, biomedical, electronics, consumer products, and repair and refurbishment of high value components.vrcmetalsystems.com

Sponsor

Supporter

Because there may have been some late changes in tabletop assignments, some exhibitors may have a different tabletop number than was shown on their invitations and advertising. Please check this Directory for the most-up-to-date listings, as well as onsite signage.

Reasonable precautions have been taken to avoid errors in and omissions from this Directory, but ASM International does not guarantee listings herein and shall not be responsible for errors in or omission in this Directory.

Integration + Calibration

www.polycontrols.com450 444-3600

Meet Polycontrols specialist in Cold Spray and Thermal Spray technologies.

We build innovative and customized solutions for several applications from design to installation and maintenance.

THE EXPERTISE IN INTEGRATION

N2 & He Pressurization and storageCalibration

Gas Recovery & Recycling Powder Feeding

Automatic Switchover for TS Guns and System Integration

Gas conditioning, Distribution & Management

Polycontrols_pub2.indd 1 2016-10-13 13:35

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Individual particle characterization device for cold spray processes

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