ShapeCold Spray Additively Manufactured Aluminum Alloy 6061 – A Process-Structure-Property-Performance Review
This work seeks to catalogue a summary of the process-structure-property-performance (PSPP) relationships present in deposits of Cold-Spray-Additively-Manufactured (CSAM) Aluminum alloy 6061 (Al 6061). The deposition efficiency, or the success with which material is deposited as to receive bonding meeting recognized standards of testing, of CSAM Al 6061 deposits depends upon process parameters and feedstock metrics, necessitating a summary of the development and advancements of the cold spray method, as well as property considerations when choosing feedstock powders. After summarizing the challenges of cold spray, a cursory review of the property balance afforded by Al 6061 reveals what makes the alloy such a desirable choice for CSAM deposits. This material/method combination results in a deposit boasting tighter tolerances than deposits built with most fusion-based additive manufacturing (AM) methods with little oxides found within the build post-deposition comparatively. While cold spray can generate near-net components with high hardness, research is ongoing to better industrialize the technology, and the final portion of this work highlights current challenges facing the successful performance of CSAM Al 6061 components in variable load states and currently known methods for overcoming those challenges.
Materials Science and Engineering | Mechanical Engineering | Metallurgy
James Worth Bagley College of Engineering
Department of Mechanical Engineering
Kemp, John T. and Cochran, Ryan, "ShapeCold Spray Additively Manufactured Aluminum Alloy 6061 – A Process-Structure-Property-Performance Review" (2022). ME 4133/6133 Mechanical Metallurgy. 33.