Bulk fracture anisotropy in Cold-Sprayed Al 6061 deposits

Julien, Scott; Nourian‐Avval, Ahmad; Liang, Wentao; Schwartz, Tricia; Özdemir, Ozan Ç.; Müftü, Sinan

doi:10.1016/j.engfracmech.2022.108301

Cited by 21 publications

(5 citation statements)

References 51 publications

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“…For CSAM, high isotropy was observed in a plane parallel to the substrate surface [141,[199][200][201], but in a vertical or Z-direction, the material had lower strength. This behavior is presented in the literature for CSAM-ed Cu [171], Al [202], and 316L [203].…”

Section: Improving the Mechanical Propertiesmentioning

confidence: 69%

“…HT promoted a metallurgical bonding of particles, increasing cohesion, material strength, and plasticity or ductility. Dimples evidenced it in SEM images of the fracture surface [202,210,[221][222][223]. For Inconel 718, Sun et al [124] applied induction for heating the material, which represents a possibility to select the CSAM-ed part region to be HT-ed, instead of the whole material, e.g., treat only the component areas that are exposed to wear or friction.…”

Section: Improving the Mechanical Propertiesmentioning

confidence: 99%

“…Ševeček et al [351] studied the benefits of CS-ed coatings on the Zircaloy-4 hightemperature fatigue life and displacement under cyclic loading. Considering the CSAM-ed bulk, Julien et al [202] used compact tension specimens, following the ASTM E399-22 standard [352], to evaluate the fracture toughness (K IC ) of CSAM-ed Al6061. Wrought reference samples had much higher values than the CSAM-ed ones, 26.5 over 13.0 MPa•m 0.5 , resulting from the CS-ed typical microstructure and the interparticular crack growth.…”

Section: Measuring Of Propertiesmentioning

confidence: 99%

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A Review of Advances in Cold Spray Additive Manufacturing

et al. 2023

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Cold Spray Additive Manufacturing (CSAM) produces freeform parts by accelerating powder particles at supersonic speed which, impacting against a substrate material, trigger a process to consolidate the CSAM part by bonding mechanisms. The literature has presented scholars’ efforts to improve CSAM materials’ quality, properties, and possibilities of use. This work is a review of the CSAM advances in the last decade, considering new materials, process parameters optimization, post-treatments, and hybrid processing. The literature considered includes articles, books, standards, and patents, which were selected by their relevance to the CSAM theme. In addition, this work contributes to compiling important information from the literature and presents how CSAM has advanced quickly in diverse sectors and applications. Another approach presented is the academic contributions by a bibliometric review, showing the most relevant contributors, authors, institutions, and countries during the last decade for CSAM research. Finally, this work presents a trend for the future of CSAM, its challenges, and barriers to be overcome.

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Section: Improving the Mechanical Propertiesmentioning

confidence: 69%

Section: Improving the Mechanical Propertiesmentioning

confidence: 99%

Section: Measuring Of Propertiesmentioning

confidence: 99%

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A Review of Advances in Cold Spray Additive Manufacturing

et al. 2023

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“…For the N 2 -formed deposit, the fracture morphology indicated that cleavage failure occurred along the non-cohesive splatted particles, as shown in Figure 11 a. Such morphologies are quite common with CSAM coatings, as the failure initiates along the interparticle boundaries of the flattened particles [ 82 , 97 , 98 ]. However, for the He-based specimen, dimples were formed along the fractured surface ( Figure 11 b).…”

Section: Structure–property Relationshipsmentioning

confidence: 99%

Solid-State Cold Spray Additive Manufacturing of Ni-Based Superalloys: Processing–Microstructure–Property Relationships

et al. 2023

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Ni-based superalloys have been extensively employed in the aerospace field because of their excellent thermal and mechanical stabilities at high temperatures. With these advantages, many sought to study the influence of fusion-reliant additive manufacturing (AM) techniques for part fabrication/reparation. However, their fabrication presents many problems related to the melting and solidification defects from the feedstock material. Such defects consist of oxidation, inclusions, hot tearing, cracking, and elemental segregation. Consequentially, these defects created a need to discover an AM technique that can mitigate these disadvantages. The cold spray (CS) process is one additive technique that can mitigate these issues. This is largely due to its cost-effectiveness, low temperature, and fast and clean deposition process. However, its effectiveness for Ni-based superalloy fabrication and its structural performance has yet to be determined. This review aimed to fill this knowledge gap in two different ways. First, the advantages of CS technology for Ni-based superalloys compared with thermal-reliant AM techniques are briefly discussed. Second, the processing–structure–property relationships of these deposits are elucidated from microstructural, mechanical, and tribological (from low to high temperatures) perspectives. Considering the porous and brittle defects of CS coatings, a comprehensive review of the post-processing techniques for CS-fabricated Ni superalloys is also introduced. Based on this knowledge, the key structure-property mechanisms of CS Ni superalloys are elucidated with suggestions on how knowledge gaps in the field can be filled in the near future.

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“…This process was developed as a coating technique; however, it has evolved into an additive manufacturing alternative in recent years, called cold spray additive manufacturing (CSAM). This process can fabricate components with different compositions, such as Ti, [1,2] Al, [3,4] steel, [5] and Cu alloys. [6,7] Compared to other additive manufacturing (AM) processes, one of its main advantages is its capacity to process alloy systems prohibited in fusion processes, such as metal matrix composites or materials with different fusion points, which is possible for CSAM, avoiding the high-temperature harmful effects on the material resulting from its melting and rapid solidification, such as the coarse columnar grains, [8] high tensile residual stress, [9,10] and feedstock material oxidation.…”

mentioning

confidence: 99%

The Effect of the Deposition Strategy and Heat Treatment on Cold Spray Additive Manufactured 316L Stainless Steel

Vaz,

Luzin,

Salvemini

et al. 2024

Adv Eng Mater

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This study investigates the effect of heat treatment on the characteristics and properties of Cold Spray Additive Manufactured 316L stainless steel employing traditional and a new Metal Knitting strategy. 316L feedstock powder characteristics, the geometry of the bulk, microstructure, porosity, microhardness, mechanical isotropy, and residual stress were analyzed in both strategies in as‐sprayed and heat‐treated conditions. Results show that the traditional deposition strategy produced higher mechanical resistance, while Metal Knitting presented a better part geometry accuracy. The heat treatment significantly improved the material strength and the quality of the parts by recovery and recrystallization phenomena. The same microhardness and planar isotropy were achieved after heat treatment of samples produced by both strategies. A discussion about the mechanisms, microstructural, and residual stress evolution is presented.This article is protected by copyright. All rights reserved.

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Bulk fracture anisotropy in Cold-Sprayed Al 6061 deposits

Cited by 21 publications

References 51 publications

A Review of Advances in Cold Spray Additive Manufacturing

A Review of Advances in Cold Spray Additive Manufacturing

Solid-State Cold Spray Additive Manufacturing of Ni-Based Superalloys: Processing–Microstructure–Property Relationships

The Effect of the Deposition Strategy and Heat Treatment on Cold Spray Additive Manufactured 316L Stainless Steel

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