iMAPS New England Chapter

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Abstract:  This presentation will provide a basic understanding of an emerging technology, referred to as ‘Cold Spray’, which has evolved from a laboratory curiosity to a production viable process. Cold spray is a materials deposition process whereby combinations of metallic and non-metallic particles are consolidated to form a coating or freestanding structure by means of ballistic impingement upon a suitable substrate. Cold spray is often compared with traditional thermal spray processes and although there are certain similarities, it is important to recognize the fundamental differences between them in order to determine which technique are best suited electronic applications. There is substantial data to suggest that cold spray has a niche in the marketplace; however, it must also be realized that cold spray does have limitations that should be acknowledged in order to prevent misuse of the technology.

It is my intention that this presentation will provide the means to initiate interest and to spawn the development of those applications appropriate to the cold spray process. The ability of the cold spray process to produce unique coatings that are not attainable with other coating methods has advanced this technology to essential status. Cold spray equipment is commercially available that is robotically controlled as well as those that are portable, hand-held, systems. The extremely dense, oxide free, coatings available by cold spray, allow this process to be used in such diverse application areas as corrosion control, electrical circuitry, and metals repair. The equipment and capabilities of the cold spray process continue to evolve, opening new application areas on a continued basis.

Biography: Mr. Champagne is a research materials engineer who has worked for the US Army Research Laboratory (ARL) and its predecessor organizations for over 24 years. He has been the technical leader for the Advanced Materials and Processes Team since 1986, where he conducts research and development programs in coatings and advanced materials and processing technologies. His research efforts have focused on the development of emerging technologies, which can be implemented into production and the field. He is internationally recognized as an expert in Cold Spray Technology and has established the ARL Cold Spray Center located in Aberdeen, MD whose focus is the development of cold spray applications for DOD and Industry. Over the past year he was awarded the prestigious U.S. Army Research and Development Achievement Award and also the Defense Manufacturing Excellence Award for his Research in Cold Spray. He was the editor of the first comprehensive reference book on cold spray for The Institute of Materials, Minerals and Mining (IoM3) published by Woodhead Publishing. He also serves as a Research Associate at Worcester Polytechnic Institute and as a liaison to Natick Laboratories, both located in MA. He is also a Thesis Advisor for graduate students at several universities including the Pennsylvania State University and manages over $23M in projects and programs for ARL.

About the Picture: Victor Kenneth Champagne Jr. was honored at the Pentagon in the “Hall of Heroes” on March 12, 2009 for his research achievements in ‘Super Sonic Particle Deposition’ also known as ‘Cold Spray.’ Mr. Champagne has been employed by the U.S. Army Research Laboratory for the past 25 years where he has been conducting research in Cold Spray Technology, for which he has recently received several top awards from the Army, including the prestigious U.S. Army Research and Development Achievement Award.

Mr. Champagne is known internationally as one of the most foremost experts on Cold Spray Technology and is the editor of the first comprehensive reference book on the subject, published last year by Woodhead Publishing Company. The results of his research have lead to many major technological advances for the Department of Defense and his outstanding achievements have been recognized throughout his career. In 1991, he received a commendation from General Harrison for “Dedicated Service During Desert Shield and Desert Storm,” for which he volunteered. In 2008, he received the coveted Excellence in Federal Career Award and special recognition from Senator Barbara Mikulski, at his former duty station, Aberdeen Proving Ground, MD.