Source: https://www.arl.army.mil/www/default.cfm?page=374
Timestamp: 2019-04-23 02:46:18+00:00

Document:
A U.S. Army Research Laboratory technical team was recognized by the Defense Department for its role in the development of the specification, MIL- DTL-32495, a Manufacturing Process Standard, entitled: Aluminum-Based Powders for Cold Spray Deposition. The winners led an international effort to develop a new specification that covers the requirements for procuring aluminum and aluminum-based alloy powders. These powders will be used to produce deposits utilizing a cold spray materials deposition process for the purpose of parts repair, coatings, or fabrication of freestanding structures. The 2014 Defense Standardization Program (DSP) Achievement Award was presented to the ARL team by DoD's Standardization Program Office.
Several flight-critical aerospace components made from aluminum, titanium or magnesium alloys cannot be repaired using conventional processes and must be removed from service, which costs the DOD several million dollars in replacement parts. Many of these components have long lead times and in some cases, there are no replacement parts in inventory. The U.S. Army, Navy, Original Equipment Manufacturers, Pennsylvania State University, NAVAIR's Paxutent River, FRC East and FRC Southwest sites worked together to develop test protocols, validation and acceptance requirements, process procedures and inspection requirements. The cold spray process has been implemented at Army, Navy and commercial facilities. Several aerospace components are currently being repaired, including the B-1 FEB Panel, B-1 hydraulic lines, F/18 AMAD transmission housing and UH-60 magnesium gear box sump. Several other repairs are being developed and will be transitioned upon validation.
ARL led a technical team that developed a cold spray process that accelerates aluminum alloy particles to high velocities and impacts them on the surface of magnesium alloy components. This cold spray process was demonstrated and validated to be a cost-effective, environmentally acceptable technology that could provide surface protection, as well as a method for restoring magnesium components that have been removed from service. The process can be incorporated into manufacturing and portable systems can be developed for field repair. A cold spray demonstration facility was established at the FRC East in North Carolina (formerly known as the Naval Air Depot Cherry Point). This project resulted in the implementation of cold spray by Sikorsky Aircraft Company. Both Sikorsky and the Army Program Office for the UH-60 Blackhawk helicopter have approved cold spray for use as a repair technology for one UH-60 magnesium component; with other approvals expected soon. The ARL team lead received a 2012 ESTCP Project of the Year Award for this important work.
The DOD Standardization Program Office presented the 2008 Defense Standardization Program Achievement Award to an ARL technical team on March 12, 2009. The ARL team received the award for its role in the development of MIL-DTL-3021, a Manufacturing Process Standard entitled "Materials Deposition, Cold Spray." The Defense Standardization Program's mission is to identify, influence, develop, manage and provide access to standardization processes, products and services for Warfighters and the acquisition and logistics communities. In addition, the program promotes interoperability and assists in reducing total ownership cost and in sustaining readiness.
The Defense Manufacturing Excellence Award is given annually to a small working group in the defense manufacturing community. The winner is acknowledged for having made outstanding contributions to manufacturing science and technology in the United States over the past fiscal year. The National Center for Manufacturing Sciences managed a cross-industry collaborative team that developed the use of cold spray for corrosion control. The methods developed will impact the DoD by significantly reducing corrosion-related maintenance across all military services. The project participants included all armed services branches—Army (ARL), Navy, Air Force and Marines—and the following cross-industry companies: The Boeing Company, Delphi Corporation, Ford Motor Company, CenterLine Ltd. and Solidica.
Journal papers are in black. Conference presentations are in green.
D. Tsaknopoulos, D. Cote, V. Champagne and R. Sisson, "Application of Computational Modeling to Trial and Error Minimization for Alloy Optimization," Materials Science & Technology Conference, Pittsburgh, October 8-12, 2017.
K. Fitzpatrick-Schmidt, D. Cote, R. Sisson and V. Champagne, "Dissolution of Secondary Phases in Al Alloys Using DICTRA Simulations," Materials Science & Technology Conference, Pittsburgh, October 8-12, 2017.
C. Walde, D. Cote, R. Sisson and V. Champagne, "Characterizing the Effect of Thermal Processing on Powder Al Alloys for Additive Manufacturing Applications," Materials Science and Technology 2017, Pittsburgh, October 8-12, 2017.
T. Bush, Z. Khalkhali, V. Champagne, D. Schmidt and J. Rothstein, "Optimization of Cold Spray Deposition of High-Density Polyethylene Powders," Journal of Thermal Spray Technology , 1 Sept. 2017, Volume 26, Issue 7, pp 1548-1564.
C. Walde, D. Cote, R. Sisson and V. Champagne, "Optimization of Solution Treatment Parameters for Aluminum Alloy Powders through the use of Thermal Analysis," North American Thermal Analysis Society Conference 2017, Newark, DE, August 7-10, 2017.
C. Taglienti, W. Xie, V. Champagne, A. Nardi, S. Müftü and J. Lee, "Temperature-dependent Laser-induced Projectile Impact Test of Aluminum 6061 Microspheres for Cold Spray Additive Manufacturing," Society of Engineering Science (SES) Annual Meeting/ASME-AMD Joint Conference, Boston, July, 2017.
W. Xie, A. Alizadeh-Dehkharghani, Q. Chen, V. Champagne, X. Wang, A. Nardi, S. Kooi, . Müftü and J.-H. Lee, "Dynamics and extreme plasticity of metallic microparticles in supersonic collisions," NATURE Scientific Reports, 11 July 2017.
V. Champagne, "Advancements in Cold Spray Materials," SURFIN 2017, 19-21 June 2017, Atlanta .
M. R. Rokni, S. R. Nutt, C. A. Widener, V. K. Champagne and R. H. Hrabe, "Review of Relationship Between Particle Deformation, Coating Microstructure, and Properties in High-Pressure Cold Spray," Journal of Thermal Spray Technology, 11 May 2017.
C. Walde, D.B. Cote, R.D. Sisson and V. Champagne, "Feedstock Powder Analysis for Additive Manufacturing Applications," AeroMat 2017, Charleston, SC, April 10-12, 2017.
S. Suresh, B. Bedard, T. Flanagan, S-W. Lee, H.D. Brody, X. Wang, V.R. Champagne and A.M. Dongare, "Mesoscale Modeling of Single Particle Impact induced Microstructural Evolution during Cold Spray of Aluminum Powders," TMS Annual Meeting 2017, San Diego, CA, February/March 2017.
B. Bedard, T. Flanagan, S. Suresh, A.M. Dongare, S-W. Lee, H.D. Brody, X. Wang and V.R. Champagne, "Microstructural Development During Particle/Substrate Impacts in Cold Spray of Gas Atomized Aluminum Alloy Powders," TMS Annual Meeting 2017, San Diego, February/March 2017.
T. Flanagan, B. Bedard, S. Suresh, A.M. Dongare, H.D. Brody, X. Wang, V.K. Champagne and S-W. Lee, "Mechanical Characterization of Cold Sprayed Aluminum Alloy Using Micropillar Compression," TMS Annual Meeting 2017, San Diego, February/March 2017.
M.R. Rokni, C.A. Widener, V.K. Champagne, G.A. Crawford and S.R. Nutt, "The Effects of Heat Treatment on 7075 Al Cold Spray Deposits," Surface and Coatings Technology, Volume 310, 25 Jan. 2017, pp 278-285.
D.B. Cote, B. McNally and V. Champagne, "Through-Process Modeling for the Cold Spray Process," 3rd European Cold Spray Symposium, Paris, France, December 12, 2016. Invited speaker.
V. Champagne, "Cold Spray for Hard Chrome Replacement," ASETS Defense 2016: Sustainable Surface Engineering for Aerospace and Defense, 6-8 December 2016, Orlando, FL.
V. Champagne Jr, D. Kaplowitz, V. Champagne III, C. Howe, M. West, B. McNally and M. Rokni, "Dissimilar Metal Joining and Structural Repair of ZE41A-T5 Cast Magnesium by the Cold Spray (CS) Process," Journal of Materials and Manufacturing Processes, 16 Nov. 2016, ISSN: 10426914.
W. Xie, A. Alizadeh, X. Wang, A. Nardi, S. Kooi, V. Champagne, S. Müftü and J.-H. Lee, "Prediction of Extreme Dynamic Behaviors of Aluminum Microspheres in Supersonic Consolidation," Materials Research Society (MRS) Meeting, Boston. 27 November 2016.
B. Bedard, H.D. Brody, V.R. Champagne, A.M. Dongare, A.T. Ernst, T. Flanagan, S-W. Lee, A. Nardi, S. Suresh and X. Wang, "Particle Impact Phenomena in Cold Spray of Gas Atomized Aluminum Alloy and Powders," Fall MRS Meeting 2016, Boston, November 2016.
A. Alizadeh, W. Xie, A. Kim, Q. Chen, H. Yang, X. Wang, V.K. Champagne, A. Gouldstone, J.-H. Lee and S. Müftü, "Impact Mechanics of Micron Scale Aluminum Particles in 100 - 1000 m/s Velocity Range," ASME IMECE 2016 Conference, Phoenix, November 11-17, 2016.
B. Bedard, H.D. Brody, V.R. Champagne, A.M. Dongare, A.T. Ernst, T. Flanagan, S-W. Lee, A. Nardi, S. Suresh and X. Wang, "Microstructural Development during Particle/Substrate Impacts in Cold Spray of Gas Atomized Aluminum Alloy Powders," Fall MRS Meeting 2016, Boston, November 2016.
B. Bedard, H.D. Brody, V.R. Champagne, A.M. Dongare, A.T. Ernst, T. Flanagan, S-W. Lee, A. Nardi, S. Suresh and X. Wang, "Mesoscale Modeling of Single Particle Impact induced Microstructural Evolution during Cold Spray of Aluminum Powders," Fall MRS Meeting 2016, Boston, November 2016.
B. Bedard, H.D. Brody, V.R. Champagne, A.M. Dongare, A.T. Ernst, T. Flanagan, S-W. Lee, A. Nardi, S. Sureshand and X. Wang, "Mechanical Characterization of Cold Sprayed Aluminum Alloy Using Micropillar Compression," Fall MRS Meeting 2016, Boston, November 2016.
V. Champagne and D. Helfritch, "The Unique Abilities of Cold Spray Deposition," International Materials Reviews, Volume 61, 2016 - Issue 7, pp 437-455.
D.B. Cote, B. McNally, J. Schreiber, V. K. Champagne, R. D. Sisson, "Experimental Verification and Computational Modeling for High Strain Rate Additive Manufacturing," Materials Science and Technology 2016, Salt Lake City, UT, October 24-27, 2016. Invited speaker.
J. Schreiber, T. Eden, I. Smid, D. Cote, B. McNally and V. Champagne, "Effect of Secondary Precipitate Phases on Cold Spray Particle Impact," Materials Science and Technology 2016, Salt Lake City, UT, October 24-27, 2016.
B. Barnett, M. Trexler, V. Champagne and M. Pepi, "Toxic Metal Reduction and Life Extension of Gun Barrel Liners through Cold Sprayed Refractory Metals," International Journal of Condition Monitoring and Diagnostic Engineering Management, Oct. 2016, Vol 19, No. 4.
A. G. Gavras and V. K. Champagne, "Design of Cold-Spray 6061 Aluminum Alloys for Fatigue Crack Growth Resistance in Structural Components, Coatings, and Repairs," TMS 2015 Annual Meeting, Nashille.
V. Champagne and D. Helfritch, "Critical Assessment 11: Structural Repairs by Cold Spray," Materials Science and Technology, 31(6), 2015.
J. M. Schreiber, Z. R. Omcikus, T. Eden, M. Sharma and V. Champagne, "Combined Effect of Hot Extrusion and Heat Treatment on the Mechanical Behavior of 7055 AA Processed via Spray Metal Forming," Journal of Alloys and Compounds, 617(12), 2014.
M.R. Rokni, C.A. Widener, A.T. Nardi and V.K. Champagne, "Nano Crystalline High Energy Milled 5083 Al Powder Deposited using Cold Spray," Applied Surface Science, 305(6), 2014.
M. R. Rokni, C. A. Widener, S. P. Ahrenkiel, B. K. Jasthi and V. R. Champagne, "Annealing Behaviour of 6061 Aluminum Deposited by High Pressure Cold Spray," Surface Engineering, Vol 30(5), 2014.
B. McNally, D. Belsito, L. Bassett, V. Champagne and R. Sisson, "Experimental Verification of Through-Process Modeling of Cold Spray Al Alloys," Materials Science & Technology, 10, 2014, Houston.
D. Cote, V. Champagne, R. Sisson, "Computational, Through-process Modeling for Cold Sprayed Alloy Optimization," Materials Science & Technology, 10, 2014, Houston.
M.R. Rokni, C.A. Widener and V.K. Champagne, "Microstructural Evolution of 6061 Aluminum Gas-Atomized Powder and High-Pressure Cold-Sprayed Deposition," Journal of Thermal Spray Technology, 23(3), 2014.
L Bassett, R. Sisson, V. Champagne and D. Apelian, "Simulating Particle Impact to Predict the Mechanical Properties of Cold Sprayed Alloys," TMS Annual Meeting, 2014, Orlando.
A. Birt, V. Champagne, D. Apelian and R. Sisson, "Laser Assisted Cold Spray of Ti-6Al-4V: A Process Optimization Roadmap," TMS Annual Meeting, 2014, Orlando.
A. Gavras, D. Lados and V. Champagne, "Processing and Fatigue Crack Growth Behavior of Cold-spray 6061 Aluminum Alloys," TMS Annual Meeting, 2014, Orlando.
B. McNally, D. Belsito, L. Bassett, V. Champagne and R. Sisson, "Microstructural Characterization and Analysis of Cold Spray Al Alloys," TMS Annual Meeting, 2014, Orlando.
D. Cote, B. McNally, V. Champagne and R. Sisson, "Through-process Modeling of Al Alloy Optimization for Cold Spray Processing," TMS Annual Meeting, 2014, Orlando.
M. Rokni, A. Nardi, C. Widener and V. Champagne, "Cold Spray Processing of Nanocrystalline AA5083 Al Powder," TMS Annual Meeting, 2014, Orlando.
V. Champagne and D. Helfritch, "Mainstreaming Cold Spray - Push for Applications," Surface Engineering, 30(6), 2014.
"Development of a Hand-held, High-pressure Cold Spray System for Field Repairs and Reduced Sustainment Costs," Defense Manufacturing Conference, 2014.
M. Rokni, C.Widener and V. Champagne, "Microstructural Stability of Ultrafine Grained Cold Sprayed 6061 Aluminum Alloy," Applied Surface Science, 290, 2014.
"Analysis of Thermal Powder Pre-Processing for Cold Spray Consolidation," Materials Science & Technology 2013.
"Through-Process Modeling for Cold Spray Alloy Design," Materials Science & Technology, 2013.
"Cold Spray Processing of Bulk Nanostructured Aluminum Alloys: Characterization, Evaluation, and Optimization," Materials Science & Technology, 2013.
S. Dean, J. Potter, R. Yetter, T. Eden, V. Champagne and M. Trexler, "Energetic Intermetallic Materials Formed by Cold Spray," Intermetallics, 43, 2013.
V. Champagne and D. Helfritch, "Demonstration of the Antimicrobial Effectiveness of Various Copper Surfaces," Journal of Biological Engineering, 7(8), 2013.
"Innovations in DOD Cold Spray Applications," Defense Manufacturing Conference, 2013, Kissimmee.
"Thermodynamic and Kinetic Model-Based Processing of Low Density Al Alloys," TMS, 2013, San Antonio.
"Cold Spray Processing of Bulk Nanocrystalline Aluminum AA5083," TMS, 2013, San Antonio.
"Microstructural Characterization and Analysis of Cold Spray Al Alloys," TMS, 2013, San Antonio.
"Cold-Spray Consolidation of Magnesium Alloys," PowderMet, 2013, Chicago.
V. Champagne, D. Helfritch, E. Wienhold and J. DeHaven, "Deposition of Copper Micro-Circuitry by Capillary Focusing," J. Micromech. Microeng. 23, 2013.
"Additive Fabrication Using Cold Spray Technology," Defense Manufacturing Conference, 2012, Orlando.
"Comparison of Titanium Cold Spray Coatings," ITSC, 2012, Houston.
M. Trexler, R. Carter, W. de Rosset, D. Gray, D. Helfritch and V. Champagne, "Cold Spray Fabrication of Refractory Materials for Gun Barrel Liner Applications," Materials and Manufacturing Processes, 27, (8), 2012.
"Development of a Novel Erosion Resistant Coating System for Use on Rotorcraft Blades," AHS International 68th Annual Forum & Technology Display, 2011, Virginia Beach.
M. Trexler, R. Carter, D. Helfritch and V. Champagne, "Effect of Carrier Gas Selection on Mechanical Properties of Cold Sprayed Tantalum," International Journal of Powder Metallurgy, 47(5), 2011.
V. Champagne, D. Helfritch, S. Dinavahi and P. Leyman, "Theoretical and Experimental Particle Velocity in Cold Spray," Journal of Thermal Spray Technology, 20(3), 2011.
V. Champagne, D. Helfritch, M. Trexler and B. Gabriel, "The Effect of Cold Spray Impact Velocity on Deposit Hardness," Modelling and Simulation in Mater. Sci. & Eng., 18(6), 2010.
V. Champagne, Cold Spray Materials Deposition Process - Fundamentals and Applications, Woodhead, 2007.
V. Champagne and D. Helfritch, "Electromagnetic Interference Shielding by the Cold Spray Particle Deposition of an Aluminum-Alumina Matrix," Journal of Advanced Materials, 40(1), 2008.
V. Champagne, D. Helfritch and M. Trexler, "Some Material Characteristics of Cold-Sprayed Structures," Research Letters in Materials Science Volume 2007, ID 27347, 2007.
"Corrosion Repair of Magnesium Rotorcraft Components," Aging Aircraft Conference, 2007, Palm Springs.
"Optimal Particle Size for the Cold Spray Process," ITSC, 2006, Seattle.
V. Champagne, D. Helfritch, P. Leyman, S. Grendahl and B. Klotz, "Interface Material Mixing Formed by the Deposition of Copper on Aluminum by Means of the Cold Spray Process," Journal of Thermal Spray Technology, 14(3), 2005.
V. Champagne, D. Helfritch and P. Leyman, R, Lempicki and S. Grendahl, "The Effects of Gas and Metal Characteristics on Sprayed Metal Coatings," Modeling and Simulation in Materials Science and Engineering, 13, 2005.
"Nozzle Design Influence on the Supersonic Particle Deposition Process," ASM Cold Spray Conference, 2004, Akron.
M. Grujicic, C.L. Zhao, W.S. DeRosset and D. Helfritch, "Adiabatic Shear Instability Based Mechanism for Particles/Substrate Bonding in the Cold-Gas Dynamic-Spray Process," Materials and Design, 25, 2004.
M. Grujicic, C.L. Zhao, C.Tong, W.S. DeRosset and D. Helfritch, "Analysis of the Impact Velocity of Powder Particles in the Cold-Gas Dynamic-Spray Process," Materials Science and Engineering, A368, 2004.
M. Grujicic, W. DeRosset and D. Helfritch, "Flow Analysis and Nozzle-Shape Optimization for the Cold-Gas Dynamic-Spray Process," Proc. Instn Mech. Engrs Part B: J. Engineering Manufacture, 217, 2003.
M. Grujicic, J.R. Saylor, D.E. Beasley, W.S. DeRosset and D. Helfritch, "Computational Analysis of the Interfacial Bonding between Feed-Powder Particles and the Substrate in the Cold-Gas Dynamic-Spray Process," Applied Surface Science, 219, 2003.

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