In the ever-evolving landscape of manufacturing, US-based Triton Systems, Inc. is pioneering the use of cold spray technology to revolutionize additive manufacturing (AM). Working with Triton’s customers as well as Titomic and its team of cold spray engineers and experts, Triton Systems is harnessing this cutting-edge technology to fuel innovation, amplify commercial applications, and chart a course for a future rich with possibilities in multi-metal coatings and in-situ repairs.
Triton Systems engaged Titomic in a strategic partnership in March 2020 to develop novel solutions to address applications for the United States Department of Defense. With the proven efficacy of cold spray technology steadily progressing, Triton Systems has since purchased a bespoke Titomic Kinetic Fusion® (TKF) System. This acquisition enables Triton Systems to continue advancing innovative solutions within the defence sector while exploring broader applications beyond military use.
Technical advancements with cold spray: insights from Dr. Christopher Massar
Dr. Christopher Massar, a Project Engineer at Triton Systems, stands as a proponent of the value cold spray technology can bring to modern manufacturing. “The greatest asset of cold spray is that it is a solid-state deposition process,” Massar explains. “This allows for repairs and the development of geometries without thermally damaging the base material.” This distinction from traditional high-temperature methods ensures that the integrity of materials remains uncompromised.
Dr. Massar delves deeper into the versatility of cold spray, particularly its capacity for material innovation. “The ability to develop new alloys on the fly and create functionally graded materials is a significant benefit,” he notes. Cold spray facilitates the blending of multiple powders to forge advanced materials, a feat often unachievable with conventional techniques like casting or forging.
Looking ahead, Dr Massar is optimistic about the commercial potential of cold spray. “Hopefully, cold spray will transition to commercialisation. The ability to develop and use new materials quickly should make it easily integrable into existing manufacturing processes,” he says. This adaptability is particularly beneficial for industry giants such as Boeing and GE, poised to reap the rewards of these innovative materials.
Massar also highlights the strategic advantage of cold spray for in-situ repairs, especially in the realm of DoD applications. “Cold spray’s push towards low-pressure and medium-pressure builds allows for handheld operations, significantly reducing repair times. This is crucial for maintaining the operational readiness and safety of our warfighters,” he concludes.
Capitalising on technological potential
To harvest the technical capabilities of cold spray, Titomic has been diligently working to commercialise cold spray within key industries, including defence and aerospace, to take the proven capabilities of cold spray from the laboratory or research labs and propel them into the factories and sites of industry.
For years, Titomic has worked with world-leading research organisations such as the CSIRO, ANSTO, and some of the world’s leading universities to expand the capability of cold spray and increase its potential applications. Titomic is also working with multiple partners to either meet or set the standards of cold spray applications within industries that are driven by stringent process controls.
With a dedicated team, Titomic employs a staff with over a century of combined cold spray experience and expertise, and Titomic is focused on bringing its technology to industry and to see it commercialised in a way in which few additive manufacturing technologies have achieved.
Commercial Benefits of Cold Spray: Insights from Dr Arthur Gavrin
Dr. Arthur Gavrin, Vice President of Advanced Materials at Triton Systems, provides a comprehensive view on the commercial implications of cold spray technology. “Cold spray is an additive process versus a subtractive process, which translates to less material wastage and more efficient use of resources,” he explains. Traditional manufacturing methods, often reliant on extensive machining of large billets, are inherently wasteful and time-consuming. In contrast, cold spray constructs the material incrementally, utilizing only what is necessary.
One of the significant challenges in traditional manufacturing is the supply chain for materials such as titanium. Titanium manufacturing is particularly problematic due to its high cost and long lead times. Dr. Gavrin points out, “The ability to manufacture on demand using cold spray technology simplifies inventory management and logistics. Instead of maintaining various forms of metal, you only need to store powder, which can be transformed into different forms as needed.” This streamlined approach can lead to significant cost savings and operational efficiency.
Further illustrating Triton Systems’ strategic foresight, Gavrin highlights its focus on large-scale applications. While many systems are designed to handle small parts, Triton Systems has been targeting multi-meter-scale parts from the outset. This capability is particularly valuable for government applications where producing large parts using traditional methods is both challenging and costly. “For the Department of Defense (DoD), making small parts is relatively easy with conventional methods, but larger parts become prohibitively expensive,” Gavrin explains. “Cold spray technology allows us to bypass the need for large billets and complex forging molds.”
Gavrin emphasizes the broader commercial potential of cold spray by recounting an example of Triton Systems’ past innovations. A technology initially developed for welding plastic in RF fields subsequently found applications in medical cancer treatments. “We look at technologies developed for the government and explore dual-use applications for commercial markets,” he states. This approach maximizes the return on R&D investments and opens new revenue streams.
The significance of cold spray technology for DoD applications cannot be overstated. Gavrin aligns his views with those of Massar, noting, “We aim to support the Department of Defense by protecting the warfighter and ensuring their safety. The ability to perform in-situ repairs with cold spray technology is crucial for maintaining operational readiness and effectiveness in the field.” This dual focus on defence and commercial applications ensures that Triton Systems’ innovations have far-reaching impacts.
In summary, cold spray technology represents a significant advancement in additive manufacturing, offering unparalleled efficiencies and broad commercial potential. Triton Systems, with its strategic partnership with Titomic, is well-positioned to lead this innovative wave in both defence and commercial sectors.
Paving the Way for the Future with Cold Spray AM
Cold spray technology heralds a new era in additive manufacturing. Its capability to create complex, multi-material parts without thermal degradation unlocks unprecedented opportunities for innovation in both commercial and government sectors. The potential for in-situ repairs enhances operational efficiency and minimizes downtime, which is critical in defence applications.
Triton Systems’ unwavering commitment to advancing cold spray technology places it at the forefront of this transformative field. As powder development evolves to match the capabilities of cold spray machines, the technology’s versatility and adoption will continue to expand. The synergy between R&D and commercialization efforts ensures that cold spray will remain a driving force in manufacturing, offering new solutions and efficiencies across various industries.
In summation, cold spray technology represents a monumental leap forward in additive manufacturing, with Triton Systems leading the charge. The technical and commercial benefits articulated above underscore the profound potential of this innovative process. With ongoing advancements and strategic applications, the future of cold spray AM shines brightly.
Cold spray additive: not just a pipe dream
Titomic has developed some of the world’s leading cold spray systems, capable of both additive manufacturing and advanced multi-metal coatings. With this technology, Titomic is bringing new manufacturing and repair capabilities
What are common cold spray materials and metals?
Common metals, such as:
- Titanium and titanium alloys
- Invar
- Aluminium and blends
- Nickel blends
- Copper and blends
- Metal carbides
- Zinc-based blends
- Silver and blends
- Tin-based blends
- Tantalum
- Gold
And, high performance alloys such as:
- AISI 4330,
- Ti-6AI-4V,
- Inconel 718
- Invar36.
Learn more about which materials you can combine to combat wear, corrosion, and more.
