Optimization of Al & Ti alloy build-up properties for Additive Manufacturing and repair applications

In aerospace applications, materials with high strength to weight ratios along with properties such as excellent corrosion resistance, lightweight, creep resistance and high thermal strength are needed. Also, cost parameters need to be considered without compromising with quality. In accordance with the properties required; aluminium and titanium alloys are most widely used in aerospace industries for aircraft structures and components. It has been found that the aluminium alloys are the major contributors for aircraft components. The aluminium alloys (2xxx, 6xxx, and 7xxx) are found to be the prominent ones. Present work demonstrates, enhanced mechanical properties of Al-alloys and Ti-alloys developed by the cold spray process for repair application and additive manufacturing aircraft structural components. The influence of different cold spray parameters on the mechanical properties of the deposited alloys were investigated. Process parameters has been optimized in respect of tensile strength, fatigue strength and hardness of the cold sprayed aluminium and titanium alloys. Using the optimized parameters, free-standing and additively manufactured components were produced and characterized to demonstrate the potential of cold spray process as an innovative process for additive manufacturing.