Cold Spray Additive Manufacturing: Spray Angles, Microstructure, and Properties

SAND2024-13281A TMS 2025 Abstract Title: Cold Spray Additive Manufacturing: Spray angles, microstructure, and properties Authors: Michael Kracum, Chris Roper, Jacob Williamson Abstract: Cold Spray Additive Manufacturing (CSAM) provides a pathway for AM fabrication of materials that are challenging to fabricate with melt-based AM techniques. Building vertical walls using spray processes with gaussian-like spray plumes requires off-normal spray angles in order to produce near-net shape walls. Off-normal deposition will affect material build rate and microstructure, with concomitant effects on mechanical properties. Recent work at SNL fabricating CSAM shapes using copper and Al-6061 will be presented. The effects of spray angle on microstructure and tensile testing from sections of larger, 3D shapes will be discussed, as well as lessons learned about toolpath development for CSAM compared to traditional melt-based AM processes. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc.