Faculty Advisor or Committee Member

Danielle Cote, Advisor

Faculty Advisor or Committee Member

Richard Sisson, Department Head

Faculty Advisor or Committee Member

Yu Zhong, Committee Member

Faculty Advisor or Committee Member

Adam Powell, Committee Member

Faculty Advisor or Committee Member

Mei Yang, Committee Member

Faculty Advisor or Committee Member

Victor Champagne, Committee Member

Identifier

etd-042319-081425

Abstract

Cold Spray is a solid-state additive manufacturing process that uses metallic feedstock powders to create layers on a substrate through plastic deformation. This process can be used for the repair of mechanical parts in the aerospace industry as well as for structural applications. Aluminum alloy powders, including Al 6061, 7075, 2024, and 5056, are typically used in this process as feedstock material. Since this process takes place all in the solid state, the properties and microstructure of the initial feedstock powder directly influence the properties of the final consolidated Cold Spray part. Given this, it is important to fully understand the internal powder microstructure, specifically the secondary phases as a function of thermal treatment. This work focuses on the understanding of the internal microstructure of Al 6061, 7075, 2024, and 5056 through the use of light microscopy, scanning electron microscopy, transmission electron microscopy, energy dispersive x-ray spectroscopy, electron backscatter diffraction, and differential scanning calorimetry. Thermodynamic models were used to predict the phase stability in these powders and were calibrated using the experimental results to give a more complete understanding of the phase transformations during thermal processing.

Publisher

Worcester Polytechnic Institute

Degree Name

PhD

Department

Materials Science & Engineering

Project Type

Dissertation

Date Accepted

2019-04-17

Accessibility

Restricted-WPI community only

Subjects

aluminum, cold spray, computational modeling, microstructure, powder

Available for download on Saturday, April 23, 2022

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