Rapidly Solidified Gas-Atomized Aluminum Alloys Compared with Conventionally Cast Counterparts: Implications for Cold Spray Materials Consolidation

In this work, three commercially available aluminum alloy systems (Al 2024, Al 6061, and Al 7075) were considered to explicitly capture the differences in material properties associated with a rapidly solidified, gas-atomized particulate feedstock as compared with their conventionally cast counterparts. Differences between the microstructural, thermodynamic, mechanical, and kinetic behaviors associated with gas-atomized and conventionally bulk counterparts have been tacitly assumed by the cold spray community. However, many researchers continue to utilize legacy properties from bulk materials when simulating particle impact phenomena in silico, for example. By way of recognizing the fact that bulk material properties may not serve as substitutes for gas-atomized powder property input parameters for cold spray process simulation and computation in silico, enhanced cold spray research and development will be more easily achieved. Therefore, understanding the feedstock powder characteristics for use in cold spray can lead to fine-tuning the properties of cold spray consolidations. Optical microscopy, scanning electron microscopy, nanoindentation, microhardness, differential scanning calorimetry, elemental analysis, and cooling rate calculations were utilized. This work confirms preliminary findings that powder alloys may not be treated the same way as their bulk counterparts in so far as the enactment of heat treatment processing parameters are concerned. Specifically, vast discrepancies were found in the grain size, secondary phases, and mechanical behavior between the powder and cast versions of each alloy.