Through-Process Modeling of Al Alloy Optimization for Cold Spray Processing

Military aircraft that require high maneuverability, durability, ballistic protection, reparability, and energy efficiency need structural alloys with low density, high toughness, and high strength. The cold spray process is a powder consolidation technique producing materials that meet these criteria. Through-process modeling will be utilized as a predictive tool to design optimum materials and processing parameters for the cold spray process. The five stages in the through-process model are powder production, powder preparation, cold spray processing, particle impact, and post-processing.  Microstructure and microchemistry development during powder production and preparation as well as deformation and microstructure changes during the cold spay process will be discussed.