Browse > Article

Repair of Mold by Cold Spray Deposition and Mechanical Machining  

Kang Hyuk-Jin (서울대학교 대학원)
Jung Woo-Gyun (서울대학교 대학원)
Chu Won-Sik (서울대학교 대학원)
Ahn Sung-Hoon (서울대학교 기계항공공학부)
Publication Information
Journal of the Korean Society for Precision Engineering / v.23, no.7, 2006 , pp. 101-107 More about this Journal
Abstract
Cold gas dynamic spray or cold spray is a novel manufacturing method for coatings. Cold spray is a high rate and direct material deposition process that utilizes the kinetic energy of particles sprayed at high velocity (300-1,200m/s). In this research, a technique to repair the damaged mold by cold spray deposition and mechanical machining was proposed. An aluminum 6061 mold with three-dimensional surface was fabricated, intentionally damaged and material-added by cold spray, and its original geometry was re-obtained successfully by Computer Numerical Control (CNC) machining. To investigate deformation of material caused by cold spray, deposition was conducted on thin aluminum plates ($100mm{\times}100mm{\times}3mm$). The average deformation of the plates was $205{\sim}290{\mu}m$ by Coordinate Measurement Machine (CMM). In addition, the cross section of deposited layer was analyzed by scanning electron microscopy (SEM). To compare variation of hardness, Vickers hardness was measured by micro-hardness tester.
Keywords
Cold spray; Aluminum particle; Deposition; Mechanical machining; Rapid manufacturing;
Citations & Related Records
Times Cited By KSCI : 5  (Citation Analysis)
연도 인용수 순위
1 Ahn, J. H., Park, K., Kim, C. K., Park, B. C. and Choi, S. R., 'Development of Rapid Tooling Processes Based on Three-Dimensional CAD/CAM,' Korean Society for Precision Engineering, Jun-Nam, May, pp. 3-6, 2001   과학기술학회마을
2 Jeng, J. Y. and Lin, M. C., 'Mold fabrication and modification using hybrid processes of selective laser cladding and milling,' Journal of Materials Processing Technology, Vol. 110, pp. 98-103, 2001   DOI   ScienceOn
3 Steenskiste, T., Smith, J., Teets, R., Moleski, J., Gorkiewicz, D., Tison, R., Marantz, D., Kowalsky, K., Riggs, W., Zajchowski, P., Pilsner, B., McCune, R. and Barnett, K., 'Kinetic Spray Coatings,' Surface and Coatings Technology, Vol. 111, pp. 62-71, 1999   DOI   ScienceOn
4 Zhao, Z., Gillispie, B. and Smith, J., 'Coating Deposition by the Kinetic Spray Process,' Surface and Coatings Technology, 2005. (In press)   DOI   ScienceOn
5 Morgan, R., Fox, P., Pattison, J., Sutclife, C. and O'Neill, W., 'Analysis of cold gas dynamically sprayed aluminum deposition,' Materials Letters, Vol. 58, pp.1317-1320, 2004   DOI   ScienceOn
6 Kim, H. J., Lee, C. H. and Hwang, S. Y, 'Fabrication of WC-Co Coatings by Cold Spray Deposition,' Surface and Coatings Technology, Vol. 191, pp. 335-340, 2005   DOI   ScienceOn
7 Kim, H. J., Lee, C. H. and Kweon, Y. G, 'Cold Gas Dynamic Spraying Process,' The Korean welding Society, Vol. 20, No.4, pp. 53-60, 2002   과학기술학회마을
8 Jee, H. S. and Seo, J. H., 'Direct Metal Deposition (DMD);Rapid Tooling; laser cladding; materials' Society of CAD/CAM Engineers, Vol. 8, No.3, pp. 150-156, 2003
9 Lee, H. Y., You, Y. H., Lee, Y. C., Hong, Y. P. and Ko K. H., 'Cold Spray of SiC and $Al_2O_3$ with Soft Metal Incorporation,' Thermal Spray Technology, Vol. 13, pp. 184-190, 2004   DOI   ScienceOn
10 Gilmore, D., Karthikeyan, J., Kay, C., Lindermann, J. and Berndt, C., 'Particle Velocity and Deposition Efficiency in the Cold Spray Process,' Thermal Spray Technology, Vol. 8, pp. 576-582, 1999   DOI   ScienceOn
11 Kang, H. J., Ahn, S. H., Lee, J. S. and Lee, J. H., 'Surface Modification of Aluminum by Nitrogen Ion Implantation,' International Journal of Precision Engineering and Manufacturing, Vol. 7, No.2, pp. 57-61,2006
12 Lee, H. Y., Yu, Y. H., Lee, Y. C., Hong, Y. P. and Ko, K. H., 'Interfacial Studies between Cold-sprayed $WO_3,\;Y_2O_3$ Films and Si Substrate,' Applied Surface Science, Vol. 227, pp. 244-249, 2004   DOI
13 Clyne, T. and Gill, S., 'Residual Stresses in Thermal Spray Coatings and Their Effect on Interfacial Adhesion: A Review of Recent Work,' Thermal Spray Technology, Vol. 5, pp. 401-406, 1996   DOI
14 Lee, H. Y., Jung, S. H., Lee, S. Y., You, Y. H. and Ko, K. H., 'Correlation between $Al_2O_3$ Particles and Interface of $Al-Al_2O_3$ Coatings by Cold Spray,' Applied Surface Science, 2005(In press)
15 Kang, H. K. and Kang, S. B., 'Tungsten/Copper Composite Deposits Produced by a Cold Spray,' Scripta Materialia, Vol. 49, pp. 1169-1174, 2003   DOI   ScienceOn
16 Steenskiste, T., Smith, J. and Teets, R., 'Aluminum Coatings via Kinetic Spray with Relatively Large Powder Particles,' Surface and Coatings Technology, Vol. 154, pp. 237-252, 2002   DOI   ScienceOn
17 Novoselova, T., Fox, P., Morgan, R. and O'Neill, W., 'Experimental Study of Titanium! Aluminum Deposits Produced by Cold Gas Dynamic Spray,' Surface and Coatings Technology, 2005(In press)   DOI   ScienceOn
18 Steenskiste, T., 'Kinetic spray: A New Coating Process,' Key Engineering Material, Vol. 197, pp. 59-86, 2001   DOI