Improving the Interparticle Bonding and Ductility of Cold Sprayed Aluminum Alloys by Deformation Processing

Abstract Cold spray (CS) can produce thick coatings and free-standing bulk materials is adaptable to additive manufacturing, including on-site repair. However, the structural applications of CS have been limited by inherently incomplete interparticle metallurgical bonding in materials. In this work, an ultrasonic washing test (UWT) was used semi-quantitatively assess extent Al6061 Al2024 relation key parameters post-CS deformation processing. Results indicate that spraying with a lighter gas or softer powder promotes bonding, although full hardly achieved even at high deposition efficiencies. Sprayed particles remain deposit only because they acquire partial sufficient prevent them from bouncing off. Post-CS rolling T6 heat treatment increase hence ductility Al alloys. Ultrasonic ironing (UI), new processing technique, also produces similar effects. The increased arise fragmentation oxide layers inherited particle surfaces consequent metal-to-metal joining boundaries.