Cold gas-dynamic spray is a solid-state materials consolidation technology that has experienced successful adoption within the coatings, remanufacturing and repair sectors of the advanced manufacturing community. As of late, cold spray has also emerged as a high deposition rate metal additive manufacturing method for structural and nonstructural applications. As cold spray enjoys wider recognition and adoption, the demand for versatile, high-throughput and significant methods of particulate feedstock as well consolidated materials characterization has also become more notable. In order to address the interest for such an instrument, nanoindentation is presented herein as a viable means of achieving the desired mechanical characterization abilities. In this work, conventionally static nanoindentation testing using both Berkovich and spherical indenter tips, as well as nanoindentation using the continuous stiffness measurement mode of testing, will be applied to a range of powder-based feedstocks and cold sprayed materials.

In this work, the influence of thermal pre-processing upon the microstructure and hardness of Al 6061 feedstock powder is considered through the lens of cold spray processing and additive manufacturing. Since solid-state cold spray processes refine and retain microstructural constituents following impact-driven and high-strain rate severe plastic deformation and bonding, thermal pre-processing enables application-driven tuning of the resultant consolidation achieved via microstructural and, therefore, mechanical manipulation of the feedstock prior to use. Microstructural analysis was achieved via X-ray diffraction, scanning electron microscopy, transmission electron microscopy, electron backscatter diffraction, energy dispersive spectroscopy, and differential thermal calorimetry. On the other hand, nanoindentation testing and analysis were relied upon to quantify pre-processing effects and microstructural evolution influences on the resultant hardness as a function of time at 540 °C. In the case of the as-atomized powder, β-Mg2Si-, Al-Fe-, and Mg-Si-type phases were observed along polycrystalline grain boundaries. Furthermore, after a 60 min hold time at 540 °C, Al-Fe-Si-Cr-Mn- and Mg-Si-type intermetallic phases were also observed along grain boundaries. Furthermore, the as-atomized hardness at 250 nm of indentation depth was 1.26 GPa and continuously decreased as a function of hold time until reaching 0.88 GPa after 240 min at 540 °C. Finally, contextualization of the observations with tuning cold spray additive manufacturing part performance via powder pre-processing is presented for through-process and application-minded design.