This study introduces a computationally efficient framework that combines an adaptive slicing algorithm and process-specific toolpath planning strategies, designed to optimise deposit accuracy and material efficiency with respect to the model of the part to fabricate. Central to this approach is the integration of predictive models for cold spray deposition, which utilise deep neural networks trained on data from physics-based analytical models.

The framework demonstrates significant improvements in efficiency and accuracy over conventional approaches, paving the way for broader adoption of cold spray additive manufacturing in complex industrial applications.

The post Enhanced geometrical control in cold spray additive manufacturing through deep neural network predictive models appeared first on Archès Lab.

Cold Spray is gaining attention in additive manufacturing for its fast deposition rates, minimal thermal effects, and flexibility in material selection and part size. However, shape control remains a key challenge. The low resolution of spray spots often leads to waviness, tapering, and edge losses, making it harder to achieve precise geometries.

This review takes a closer look at the current efforts to characterize and predict Cold Spray deposit shapes and explores strategies for improving geometrical control, including advanced trajectory planning techniques.

The post Cold Spray Additive Manufacturing: A Review of Shape Control Challenges and Solutions appeared first on Archès Lab.

Last week, our team members showcased their latest work on simulating cermet deposition and assessing the structural integrity of cold spray deposits at the International Conference on Surface Modification Technologies (SMT36) in Barcelona.

This event provided a fantastic platform to engage with academic colleagues and industry experts.

The post Archès Lab joins the International Conference on Surface Modification Technologies in Barcelona appeared first on Archès Lab.

This 18 month project aims to innovate the repair and regeneration of mechanical components using Cold Spray (CS) technology, incorporating analytical models and artificial intelligence. This innovation will significantly reduce post-processing, material waste and delivery times in the manufacturing industry, contributing to sustainability and accessibility in repairs through fully automated tools.

The post Kick-off of Archès Lab’s new ERC-PoC project appeared first on Archès Lab.

“Exploring the bonding mechanism in cold spray deposition of engineered graphene nanoplates-Ni nanocomposite powder“

Graphene’s excellent properties make it an ideal reinforcement for Metal Matrix Composites (MMCs), enhancing strength, elasticity, and thermal conductivity. Traditional manufacturing methods like powder metallurgy and additive manufacturing require high temperatures, risking damage to graphene. Cold spray (CS) offers a promising alternative, operating at low temperatures to deposit composites with minimal oxidation and particle coarsening, resulting in improved wear resistance and friction properties. However, the bonding mechanisms between graphene nanoplatelets (GNPs) and the metal matrix, as well as the effects of GNP content and particle velocity, are not fully understood. Molecular dynamics (MD) simulations, by examining the processes at the atomic level, can provide crucial insights into these interactions, making them a powerful tool for optimizing CS-based GNP-MMC production.

This study employs molecular dynamics simulations to examine the cold spray process of a single graphene-Ni composite powder particle impacting a Ni substrate, with the aim of gaining deeper insights into the underlying bonding mechanisms of such materials. The effect of impact velocity on deposition is investigated by testing velocities ranging from 300 to 1500 m/s, focusing on common cold spray phenomena such as bounce-off and plastic deformation. Furthermore, the research explores the impact of varying graphene content on the metal-metal bonding phenomenon, enhancing the practical relevance of the study. As a further advancement, microstructural changes during the plastic deformation of composite powders are monitored through particle-on-particle deposition simulations.

The post Exploring the bonding mechanism in cold spray deposition of engineered graphene nanoplates-Ni nanocomposite powder appeared first on Archès Lab.

Cermet materials comprising ceramic and metallic constituents demonstratesuperior mechanical properties, rendering them highly appropriate for dem-anding applications. Studies have shown that cold spray (CS) technology is a viable method for producing cermet coatings and components. CS effectively embeds the ceramic phase, which acts as reinforcement, within the metallic matrix. The paper presents a comprehensive review of diverse aspects of cermet depositsobtained using CS technology.

The post Current Trends and Future Perspective for Cold SprayMetal-Ceramic Composites appeared first on Archès Lab.

The post Advancing the next generation of high-performance metal matrix composites through metal particle reinforcement appeared first on Archès Lab.

The ability to adjust topological features of lattice structures offers a great potential to finely calibrate their physical and mechanical response to precisely meet specific requirements. This study explores a new topological design that leverages the internal porosity of Triply Periodic Minimal Surfaces (TPMS) unit cells to optimize and control their mechanical properties. A smaller-scale TPMS lattice structure was integrated within the internal volume of the sheet-network Schwarz Primitive TPMS cell, culminating in a hybrid hierarchical architecture. Various TPMS topologies with distinct mechanical behavior and varying relative density combinations were examined. Experimental and numerical approaches were developed to reveal the structure’s deformation behaviour and quantify stiffness, anisotropy, quasi-static uniaxial compressive strength, and energy absorption capacity. The topological design of the internal lattice was found to play a key role in defining the mechanical performance of the integrated structures, leading to enhanced energy absorption up to 4 times that of the reference structure. Moreover, all the studied hierarchical topologies exhibited a lower Emax/Emin ratio in comparison to the reference topology, indicating more isotropic performance of the hybrid designs (upto 40% reduction of anisotropy). The findings underscore the significant promise of hybrid hierarchical design methodologies in attaining lattice structures with tailored properties.

The post A novel hierarchical triply periodic minimal surface unit cell  appeared first on Archès Lab.

Our researchers at Archès Lab have concluded a stimulating period for dissemination activities!

During the first weeks of September, we were pleased to attend the 53rd Associazione Italiana per l’Analisi delle Sollecitazioni (AIAS) conference in Naples, Italy, the North American Cold Spray Conference (NACSC) in Boucherville, Canada and the Additive Manufacturing Meets Medicine (AMMM) conference in Lübeck, Germany.

Below you can find a list of all of our contributions.

AIAS2024

• Exploring the Mechanical properties of metallic powder particles for Cold Spray deposition. Authors: A. Heydari Astaraee, A. Badino, F. Delloro, M. Guagliano, S. Bagherifard
• Progettazione del processo di Cold Spray Additive Manufacturing traminte tecniche di Deep Learning. Authors: R. Falco, M. Jalayer, M. Guagliano, S. Bagherifard
• Design and characterization of hybrid hierarchical lattice structures based on sheet-network triply periodic minimal surface topology. Authors: R. Yousefi Nooraie, G. Di Frisco, M. Guagliano, S. Bagherifard
• A comparative life cycle assessment of additive manufacturing processes, with focus on cold spray deposition. Authors: M.M. Thakkar, S. Bagherifard, M. Guagliano

NACSC

• Towards Shape Control in Cold Spray Additive Manufacturing. Invited speaker: S. Bagherifard

AMMM

• Inverse multi-objective design of heterogeneous cellular structures. Authors: R. Yousefi Nooraie, M. Guagliano, S. Bagherifard

The post Archès Lab’s September dissemination activities appeared first on Archès Lab.

The post Prof. Sara Bagherifard’s Plenary Lecture at the European Conference on Fracture (ECF24) appeared first on Archès Lab.