Microstructure and Micromechanical Response in Gas-Atomized Al 6061 Alloy Powder and Cold-Sprayed Splats

Bedard, Benjamin A.; Flanagan, Tyler J.; Ernst, Alexis T.; Nardi, Aaron; Dongare, Avinash M.; Brody, H. D.; Champagne, Victor K.; Lee, Seok‐Woo; Aindow, Mark

doi:10.1007/s11666-018-0785-0

Cited by 38 publications

(30 citation statements)

References 68 publications

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“…EBSD informed nanoindentation analysis found that the orientation aligned with the [111] direction had a hardness of 1.25 GPa while the [101] direction had a hardness of 0.73 GPa, as shown in Figure 27. The average hardness was determined to be 1.17 GPa for the powder which is consistent with gas-atomized Al 6061 powder as reported in [7,38,77].…”

Section: Orientation-dependent Powder Propertiesmentioning

confidence: 97%

“…Additionally, the nanoindentation modulus of elasticity of the powder grains as a function of crystallographic orientation was measured. The grain aligned with the [111] direction had a modulus of 74.12 GPa while the grain aligned with the [101] direction had an elastic modulus of 65.34 GPa.…”

Section: Orientation-dependent Powder Propertiesmentioning

confidence: 99%

“…Otherwise, an increased concentration of dislocations from severe plastic deformation could also be generated more readily via grains that have a [111] orientation regardless of strength. Dislocation accumulation at prior grain boundaries is alleged to drive the dynamic recrystallization.…”

Section: Prospective Implications For Cold Spraymentioning

confidence: 99%

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Nanomechanical Characterization for Cold Spray: From Feedstock to Consolidated Material Properties

Sousa

Gleason

Haddad

et al. 2020

Metals

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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.

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Section: Orientation-dependent Powder Propertiesmentioning

confidence: 97%

Section: Orientation-dependent Powder Propertiesmentioning

confidence: 99%

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Nanomechanical Characterization for Cold Spray: From Feedstock to Consolidated Material Properties

Sousa

Gleason

Haddad

et al. 2020

Metals

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“…Per the need for continued consideration of the literature reported to date surrounding gas-atomized Al 6061 powder particle microstructures, Bedard et al was considered first herein. More to the point, Bedard et al claimed to have observed "cell-like solidification microstructures" in their Al 6061 feedstock [42]. Beyond the work of Bedard et al, Ernst et al purported that "cellular-dendritic", i.e., compound-like, solidification microstructures were observable in another gas-atomized Al 6061 powder [43].…”

Section: Resultsmentioning

confidence: 99%

Thermal Preprocessing of Rapidly Solidified Al 6061 Feedstock for Tunable Cold Spray Additive Manufacturing

Haddad

Sousa

Tsaknopoulos

et al. 2022

Metals

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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.

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“…It has been seen that SEM can be insufficient to show secondary phases of a few micron diameter; therefore, transmission electron microscopy (TEM) is preferred [ 16 , 17 , 18 , 19 , 20 ] to observe the submicron phases. Samples were created for TEM imaging using a gallium focused ion beam (FIB) (FEI Helios 660 Nanolab and FEI Scios Dual Beam FIBs) in a method similar to that employed by Tsaknopoulos et al [ 17 ].…”

Section: Methodsmentioning

confidence: 99%

Characterization of Thermally Treated Gas-Atomized Al 5056 Powder

et al. 2020

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Aluminum 5056 is a work-hardenable alloy known for its corrosion resistance with new applications in additive manufacturing. A good understanding of the secondary phases in Al 5056 powders is important for understanding the properties of the final parts. In this study, the effects of different thermal treatments on the microstructure of Al 5056 powder were studied. Thermodynamic models were used to guide the interpretation of the microstructure as a function of thermal treatment, providing insight into the stability of different possible phases present in the alloy. Through the use of transmission electron microscopy (TEM) and energy-dispersive X-ray spectroscopy (EDS), combined with thermodynamic modeling, a greater understanding of the internal microstructure of Al 5056 powder has been achieved in both the as-atomized and thermally treated conditions. Evidence of natural aging within these powders was observed, which speaks to the shelf-life of these powders and the importance of proper treatment and storage to maintain consistent results.

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Microstructure and Micromechanical Response in Gas-Atomized Al 6061 Alloy Powder and Cold-Sprayed Splats

Cited by 38 publications

References 68 publications

Nanomechanical Characterization for Cold Spray: From Feedstock to Consolidated Material Properties

Nanomechanical Characterization for Cold Spray: From Feedstock to Consolidated Material Properties

Thermal Preprocessing of Rapidly Solidified Al 6061 Feedstock for Tunable Cold Spray Additive Manufacturing

Characterization of Thermally Treated Gas-Atomized Al 5056 Powder

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