An updated viscoplastic self-consistent model to capture the effects of residual stress, microstructural heterogeneity, and precipitation in cold-sprayed aluminum alloys

Author

Aulora Williams, Mississippi State UniversityFollow

ORCID

https://orcid.org/0009-0005-1996-5798

Advisor

Rhee, Hongjoo

Committee Member

Mujahid, Shiraz

Committee Member

Paudel, YubRaj

Committee Member

Brauer, Shane

Date of Degree

5-16-2025

Original embargo terms

Embargo 6 months

Document Type

Dissertation - Open Access

Major

Engineering (Mechanical Engineering)

Degree Name

Doctor of Philosophy (Ph.D.)

College

James Worth Bagley College of Engineering

Department

Michael W. Hall School of Mechanical Engineering

Abstract

Cold spray additively manufactured (CSAM) aluminum alloys exhibit heterogenous microstructures and mechanical properties, primarily due to high dislocation densities, sub-grain structures, and variation in inter-particle (intersplat) bonding arising from high-velocity particle impacts. Thermal post-processing has been shown to enhance intersplat bonding, reduce high residual stress concentrations, and lower dislocation densities, thereby improving the overall mechanical properties. Building on previous advancements with a mean-field viscoplastic self-consistent (VPSC) model, integrating intersplat boundary terms, Hall-Petch relations, and physically informed residual stress parameters, the current work extends the model to include precipitates and their effects. Observations of CSAM aluminum 7050 alloy indicate precipitate congregation at intersplat boundaries, which contribute to the material’s deformation response. Incorporating effects of these precipitates into the VPSC model would allow for more accurate predictions of the stress-strain behavior in cold-sprayed aluminum 7050 alloy, enhancing the model’s applicability to CSAM aluminum alloys.

Sponsorship (Optional)

The authors gratefully acknowledge support from The Office of the Secretary of Defense (OSD), DEVCOM - Army Research Laboratory and LIFT through grants "W911NF2020206" and “K005-01 PROJECT\# 21025”, entitled, “RAD – Advanced Additive Manufacturing and High Throughput Materials Discovery” and “Research Utilizing the Chemistry–Process–Structure–Property–Performance (CPSPP) Paradigm”

Recommended Citation

Williams, Aulora, "An updated viscoplastic self-consistent model to capture the effects of residual stress, microstructural heterogeneity, and precipitation in cold-sprayed aluminum alloys" (2025). Theses and Dissertations. 6595.
https://scholarsjunction.msstate.edu/td/6595