Within the framework of the Industry 4.0 cross-cutting theme, the ICB Laboratory is exploring new avenues for the additive manufacturing of large composite parts. The latest demonstration is the hybridization of the WAAM (Wire Arc Additive Manufacturing) and cold-spray processes.
This innovative combination enables the rapid production of parts incorporating materials with complementary properties. The WAAM process fabricates a metallic structure by stacking weld beads, while cold-spray projects metallic particles at very high speed using a carrier gas, thus ensuring a dense and adherent deposit.
A bi-material part made of aluminum and copper
In this feasibility phase, a component was created consisting of a 4043 aluminum structure (AlSi5 synergistic curve – CMT advanced process) and copper walls deposited by cold-spray.
A U-shaped reinforcement, integrated into the aluminum structure, prevented any deformation during machining or high-pressure spraying. The ductility of 4043 aluminum also ensures excellent adhesion of the copper powder coating.
A training and innovative project
Two high school sophomores, Jules PELLETIER and Hermione VERDY, were able to follow the various stages of the manufacturing process: surface preparation, part assembly, robotic programming, and cold-spray application. It was an enriching immersion into the world of additive manufacturing and hybrid processes.
🎥 Watch the demonstration video
Cette réussite illustre le potentiel de l’hybridation WAAM–cold-spray pour concevoir des pièces multi-matériaux performantes et ouvre la voie à de nouvelles applications industrielles.
