Thermography-Assisted Mechanical Testing of Cold-Spray (AM) Repair

  • Cold Spray Additive Manufacturing (CSAM) is a solid-state process that is being increasingly used for structural repairs in aerospace and energy sectors. It enables the deposition of dense material at low temperatures by accelerating metal particles to supersonic velocities, thereby reducing thermal distortion. However, the structural integrity of CSAM repairs—particularly at the interface between the deposited layer and the substrate—remains a critical concern. Various post-treatments and characterization methods have been explored to optimize performance. While X-ray Computed Tomography (XCT) is effective for sub-surface inspection, it cannot be applied in situ during mechanical testing. Digital Image Correlation (DIC), a surface-based method, also lacks sub-surface sensitivity. To address this, Infrared Thermography (IRT) was employed alongside DIC during the tensile and fatigue testing of aluminum CSAM-repaired specimens. A cooled IRT camera operating at 200 FPS captured thermalCold Spray Additive Manufacturing (CSAM) is a solid-state process that is being increasingly used for structural repairs in aerospace and energy sectors. It enables the deposition of dense material at low temperatures by accelerating metal particles to supersonic velocities, thereby reducing thermal distortion. However, the structural integrity of CSAM repairs—particularly at the interface between the deposited layer and the substrate—remains a critical concern. Various post-treatments and characterization methods have been explored to optimize performance. While X-ray Computed Tomography (XCT) is effective for sub-surface inspection, it cannot be applied in situ during mechanical testing. Digital Image Correlation (DIC), a surface-based method, also lacks sub-surface sensitivity. To address this, Infrared Thermography (IRT) was employed alongside DIC during the tensile and fatigue testing of aluminum CSAM-repaired specimens. A cooled IRT camera operating at 200 FPS captured thermal data, with lock-in processing subsequently applied in post-processing. IRT successfully detected early interfacial damage and enabled the tracking of crack propagation, which was later confirmed through fracture surface analysis.zeige mehrzeige weniger

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Autor*innen:Somsubhro ChaudhuriORCiD
Koautor*innen:Sruthi Krishna Kunji Purayil, Julius Kruse, Mauro MadiaORCiD, Sören Nielsen
Dokumenttyp:Vortrag
Veröffentlichungsform:Präsentation
Sprache:Englisch
Jahr der Erstveröffentlichung:2025
Organisationseinheit der BAM:8 Zerstörungsfreie Prüfung
8 Zerstörungsfreie Prüfung / 8.3 Thermografische Verfahren
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Thermografie
Cold spray; Damage detection; Thermal stress analysis; Thermography
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Degradationsmechanismen
Veranstaltung:Advanced Infrared Technology and Applications (AITA) 2025
Veranstaltungsort:Kobe, Japan
Beginndatum der Veranstaltung:15.09.2025
Enddatum der Veranstaltung:19.09.2025
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:30.09.2025
Referierte Publikation:Nein
Eingeladener Vortrag (wissenschaftliche Konferenzen):Nein
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