Oliver Stier

Fundamental Cost Analysis of Cold Spray

The cost structure of the cold spray (CS) process is analyzed using a generic cost model applicable to all present types of CS systems (“high pressure,” “low pressure,” KM™, “kinetic spraying,” etc.) and kinds of application (coating, restoration, additive manufacturing, near-net forming). The cost model has originally been developed at SIEMENS and is easy to use, while being sufficiently accurate to support decisions. The dependence of the process costs on the gas stagnation properties is discussed. It is shown (i) that high pressure is generally favorable, (ii) that He-N2 blends possess economic potential, and (iii) that He recovery saves costs in high volume production, even when He-N2 blends are used. The cost model allows for the determination of the cost-optimal He concentration of the propellant gas for a given application. CS is, among others, suited to spray bond coatings on gas turbine blades and offers cost-saving potential, as shown in a case study.