Cold Spray Additive Manufacturing (CSAM)
Metallic 3D printing and repair at supersonic speeds without melting.
Read PDFCSAM (Cold Spray)
Cold Spray Additive Manufacturing
Complementary solid-state process (not part of the 7 ISO/ASTM main families). Metal powder is accelerated to supersonic velocity and bonds to a substrate via plastic deformation — no melting occurs.
Operating Principle & Process Flow
Operating Principle: A heated carrier gas (nitrogen or helium) accelerates metal particles in a Laval nozzle to Mach 2–4. On impact, particles deform plastically and "cold-weld".
Process Flow: Gas expansion in nozzle → Powder injection → Supersonic impact on substrate → Layer-by-layer build-up.
Technical Specifications
- Energy Source: Kinetic energy (no thermal melting).
- Feedstock / Material Feed: Metal powder.
- Typical Part Size: Medium to large.
- Build Rate: Very high (up to several kg/h).
- Accuracy: Low.
- Surface Quality: Rough; mandatory post-machining.
Applications & Materials
Typical Materials: Copper, aluminium, titanium, tantalum.
Typical Applications: Aerospace component repair, copper coating of battery housings.
Industries: Aerospace, e-mobility, defence.
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