Low residual stress coatings and additively manufactured components by high pressure cold spraying of cermet nanocomposites

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Today an estimated 45% of world's greenhouse gas emissions come from energy generation and industrial manufacturing, making them among the major contributors to global warming. A conscious effort is building towards finding environmentally-sustainable solutions using less material, reducing waste in manufacturing, and fabricating long-lasting products at lower costs. On the verge of industrial revolution, Industrie 4.0, a combinatory approach of high-performance material design with precision manufacturing in cyber-physical network presence is a timely response to meet the above criteria, paving the way for manufacturers to survive and prosper. The application of academic research in advanced materials and manufacturing processes in local industrial shops is a focused strategy to take on this challenge. The desired success can only be achieved when researchers look at materials from a 'bottom-up' approach, by taking advantage of a myriad of supporting technologies to unfold their nano-scale physical characteristics in them. The premise is that the new components must be built into the design at the atomic level of material crystal structures so that novel functionalities are implanted at a very early stage in their life cycle, with the ability to predict their macro-scale mechanical and physical properties. The proposed research deals with design and development of nanostructured ceramic-metallic (cermet) composites and the deposition of cermet particles as coatings and 3D, functionally-graded (FG) objects using an additive manufacturing principle, thereby deviating from traditional 'subtractive' methods. The aim is to create new knowledge in nanostructured cermets and to develop advanced surface protective solutions for industrial materials exposed to structural/nonstructural applications, including high-velocity fluid flow slurry erosion, high-temperature oxidation-corrosion, and fatigue. The objective of developing low-residual-stress and high-temperature, fatigue-resistant coatings and 3D FG components is met through design, predictive modeling, processing, characterization/testing, and field trial analysis of engineered nanocrystalline cermet particles and high pressure cold spraying (HPCS), thereby replacing current low-performance high velocity oxy-fuel technology, and creating a less wasteful manufacturing future. The success of the research depends on the integration of HQP working with three principal technologies: high-energy mechanical alloying to solid-state nanostructured particle synthesis, particle spheroidization/functionalization in fluidized, bed reactor-enabled chemical vapor deposition, and spraying of feedstock particles in HPCS in a single operation, reducing material waste. The work will create socio-economic opportunities for Canadian industrial companies, and have a positive environmental impact.