Cold Spray Additive Manufacturing: A Layered Effect

Rebecca Sinclair-Adamson, Joseph J. Bevitt, Q. B. Nguyen, Matthew Harbidge, Shannon L. Fuller, Rebecca Murray

Research output: Contribution to conferenceConference presentation/ephemera


What defines the difference between a coating and a solid? If multiple layers of coating are built up, at what point should one stop calling it a coating? Cold spray technology has been combined with a 6-axis robotic arm to create solid objects which are additively manufactured using many layers of metallic cold spray coatings. The porosity, strength and other characteristics of these cold-spray 3D printed objects are investigated.
Sections of cold-spray additively manufactured (CSAM) aluminium 6061 have been tested at The Australian Synchrotron using X-ray tomography (10µm voxel size) with the goal of understanding more about the layer structure, the inherent porosity and the effects of heat treatment. An apparently greater incidence of pores was observed at the layer boundaries (Figure 1), and differences between the outside and interior of printed objects. Heat treatment at 615°C changed the appearance of pores from substantially planar to a more spheroidal morphology (compare OM in Figure 1). Heat treatment (615°Cx240min, 550°Cx10min, WQ, 225°Cx270min) is also shown to reduce the delineation of the particle boundaries. From mechanical testing, it was found that heat treatment of CSAM aluminium 6061 increased ultimate tensile strength from 178±3 to 280±14 MPa (n=6) and the elongation to failure from 0.31±0.01% to 2.71±1.06%. Further quantitative image analysis and other examples of the properties and structure of CSAM materials will be presented.
Original languageEnglish
Publication statusPublished - 11 Feb 2020
Externally publishedYes
EventMaterials Innovations in Surface Engineering - Swinburne University of Technology, Melbourne, Australia
Duration: 10 Feb 201912 Feb 2019


ConferenceMaterials Innovations in Surface Engineering
Abbreviated titleMISE 2020


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