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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. This extended abstract presents findings from fatigue tests using IRT.zeige mehrzeige weniger

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Metadaten
Autor*innen:Somsubhro ChaudhuriORCiD, Sruthi Krishna Kunji Purayil, Julius Kruse, Mauro MadiaORCiD, Sören Nielsen
Dokumenttyp:Beitrag zu einem Tagungsband
Veröffentlichungsform:Verlagsliteratur
Sprache:Englisch
Titel des übergeordneten Werkes (Englisch):AITA 2025
Jahr der Erstveröffentlichung:2025
Organisationseinheit der BAM:8 Zerstörungsfreie Prüfung
8 Zerstörungsfreie Prüfung / 8.3 Thermografische Verfahren
Veröffentlichende Institution:Bundesanstalt für Materialforschung und -prüfung (BAM)
Verlag:MDPI
Verlagsort:Basel
Jahrgang/Band:129
Ausgabe/Heft:1
Aufsatznummer:18
Erste Seite:1
Letzte Seite:5
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:18th International Workshop on Advanced Infrared Technology and Applications (AITA 2025)
Veranstaltungsort:Kobe, Japan
Beginndatum der Veranstaltung:15.09.2025
Enddatum der Veranstaltung:19.09.2025
DOI:10.3390/proceedings2025129018
URN:urn:nbn:de:kobv:b43-642299
Verfügbarkeit des Dokuments:Datei für die Öffentlichkeit verfügbar ("Open Access")
Lizenz (Deutsch):License LogoCreative Commons - CC BY - Namensnennung 4.0 International
Datum der Freischaltung:30.09.2025
Referierte Publikation:Nein
Schriftenreihen ohne Nummerierung:Wissenschaftliche Artikel der BAM
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