AVS 64th International Symposium & Exhibition
    Manufacturing Science and Technology Group Thursday Sessions
       Session MS-ThM

Invited Paper MS-ThM1
Thermal Spray for Additive Manufacturing

Thursday, November 2, 2017, 8:00 am, Room 5 & 6

Session: Additive and Other Novel Manufacturing Techniques
Presenter: Cheng Zhang, Florida International University
Authors: A. Agarwal, Florida International University
C. Zhang, Florida International University
Correspondent: Click to Email
Additive manufacturing is gaining popularity in the commercial domain due to engineering and economic advantages over conventional manufacturing, such as reduced material wastage, lightweight components, and rapid manufacturing to near net shapes. Thermal spray processes are promising for additive manufacturing of metals, ceramics as well as polymers. Thermal spray is a wide range of manufacturing processes in which material in the form of particles/wire is sprayed and deposited at elevated temperatures to form coatings and free-standing 3D structures. These processes include plasma spray, flame spray, detonation gun, high-velocity oxyfuel spray, wire arc spray and cold gas spray. Thermal spray allows rapid processing of near net shape structures at bulk scale with complex shapes, contours, and variable thickness. Thermal spray techniques enable manufacturing of composite materials and functional gradient structures. While thermal sprayed coatings have diverse applications in wear resistance, biomedical implants, thermal barrier, corrosion protection, direct write sensors, fuel cells, etc., free-standing 3D structures fabricated by thermal spray are not as extensively used. This talk will present an overview of the state of the art of additive manufacturing via thermal spray techniques. The challenges and potential solutions will be described. A Novel in situ characterization techniques will be discussed that provide insight into processing-structure-property correlations in bulk 3D components fabricated by thermal spray. This will enable development of bulk components with predictable properties by thermal spray techniques.