Tailoring powder strengths for enhanced quality of cold sprayed Al6061 deposits

As verified by literature, heat-treatments of as-atomized Al-alloy powders before cold spraying, result in microstructural homogenization and deposition efficiency increment. So far, a straightforward correlation between powder strength consequences for the performance spraying deposit properties is still missing. This work thus provides reliable analyses strengths annealed states to calculation critical velocities quality parameter ?, as well associated influences on single-particle adhesion microstructures properties. By annealing powder, its reduced about 60%, which allows decreasing velocity successful deposition. Experimental results demonstrate that strength-based ? more realistic description characteristics deposits The impact morphologies detachment features adhering splats cavitation tests visualize respective bonding behaviors. lower contribute better single splat adhesion, porosity, higher electrical conductivity, improved tensile deposits. direct pre-annealing combination with variation defining effective strategies improving