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Breadcrumb

  1. Research
  2. Scientific Discovery
  3. Materials Sciences
  4. Solid Phase Processing
  5. Cold Spray

Cold Spray Deposition
for Material Repair

Supersonic metal
deposition to the rescue

PNNL is working on a new spray coating to repair dam turbines. The coating, called cold spray, is more effective than the current practice of welding damaged turbines.

(Photo by Andrea Starr | Pacific Northwest National Laboratory) 

  • Materials in Extreme Environments
  • Precision Materials by Design
  • Science of Interfaces
  • Solid Phase Processing
    • Cold Spray
    • Friction Stir Welding & Processing
    • ShAPE
  • News & Updates

Related Researchers

The newest addition to Pacific Northwest National Laboratory's (PNNL's) suite of solid phase processing (SPP) capabilities is cold spray. This technology is a method of depositing powder particles onto a component—most commonly metallic—at supersonic speeds. A compressed and heated gas jet propels the particles at speeds from Mach 1 to Mach 3. The resulting high-speed impact causes the powder particles to adhere to and buildup on the component, forming strong metallurgical bonds. The cold spray coating process can result in high density deposits with superior material properties compared to other metal deposition technologies.

PNNL is using its cold spray machine to research alternative approaches for repairing hydropower turbines and nuclear waste tanks. With cold spray, melting and material degradation does not occur and in the case of hydroelectric turbines, the blades remain in their original shape.

graphic depiction of cold spray

Cold spray can deposit materials that have hardness, corrosion resistance, and/or wear resistance properties that can exceed those of the base metal to provide superior equipment performance while reducing costs of repair.

Researcher holding cold spray treated component
Cold spray tests show this SPP technique is more effective than welding for repairing damaged components. (Photo by Andrea Starr | Pacific Northwest National Laboratory)

Recently, the project team demonstrated a cold spray process that delivered a material with three times improved cavitation erosion resistance compared to stainless steel plate or filler metal, and about an eight times improvement compared to the heat-affected zone carbon steels commonly used to repair hydropower turbines.

Beyond repair

Because cold spray deposits do not undergo melting during processing, the technique holds promise for additive manufacturing. Research shows the potential to create entirely new alloy systems that are otherwise incompatible in melt-based processes. In addition, cold spray allows coatings to be deposited and bonded to materials for added functions. Coatings can protect the environment or, in the case of ceramic coatings, create materials that can be used at higher temperatures than originally intended. 

Research advancements

PNNL has recently obtained a next-generation cold spray system and researchers believe that cold spray has potential to reduce cost and improve performance of new and existing components throughout the energy sector. This new, high-pressure cold spray capability will support development of cold spray processes ranging from high-volume automated factory production to manual field repair.

Related Links

Solid Phase Processing Publications Available SPP TechnologiesAwardsSPP @ PNNL

Top Stories

OCTOBER 6, 2021
Feature

Cold Spray to Help Keep Turbines Spinning

Read
Woman holding block of metal
JULY 21, 2016
Feature

Dam Operators Keep their Cool with Cold Spray Repairs

Read
hydrophoto

Featured Research

Research Topic

Materials Sciences Sustainable Energy Lightweight Materials Vehicle Technologies

Related Divisions

Energy Processes & Materials Division
Physical Sciences Division

Contacts

Chris Smith
Project Manager
christopher.smith@pnnl.gov
(509) 375-2897
Sara Hunt
Commercialization Manager
sara.hunt@pnnl.gov
(206) 528-3535

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