Erosive wear analysis of aeronautical components manufactured by cold spray additive manufacturing

Cold spray additive manufacturing (CSAM) is a technology that can be used for producing components in different industrial sectors, including aeronautics. It offers advantages over conventional techniques, reducing costs and providing an environmentally friendly option. However, exposure to the meteorological conditions can cause wear processes, including erosion. The purpose of this study is to investigate the erosion behaviour of two light alloys, extensively used in aeronautics, namely aluminium 1050 and titanium grade II, which were manufactured using CSAM. The study was conducted in accordance with the ASTM G76 standard, using alumina as the abrasive at room temperature. The abrasive flow and velocity parameters were fixed, and the impact angle was varied. To determine the erosion rate, different test durations were established. The mass loss during the erosion test was evaluated using a confocal microscope. The erosion imprints were then analysed to identify the dominant mechanisms during the erosion process. Additionally, an attempt was made to relate the morphology of the residual erosion imprints to the erosion rates. Finally, an alternative erosion model was proposed to include the effect of the impingement angle of the erosive particles.