Processing-microstructure-property relationships for cold spray powder deposition of Al-Cu alloys
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Authors
Leazer, Jeremy D.
Subjects
cold spray
aluminum copper
particle velocity
critical velocity
aluminum copper
particle velocity
critical velocity
Advisors
Menon, Sarath K.
Brewer, Luke N.
Date of Issue
2015-06
Date
Jun-15
Publisher
Monterey, California: Naval Postgraduate School
Language
Abstract
This thesis presents research on the cold gas-dynamic spray process applied to the deposition of aluminum-copper alloy coatings. Cold spray deposition is a process utilized to create corrosion protection coatings and to perform additive repair for aluminum structures. This thesis utilized a series of Al-Cu binary alloy powders, from 2–5 weight percent copper and characterized their chemistry and microstructure. The powders were deposited using the cold spray approach to study the systematic increase of the alloying agent on the deposition process and coating characteristics. Deposition efficiency, critical velocity, coating thickness, hardness, porosity, and microstructure were all characterized as functions of carrier gas pressure, carrier gas temperature and feedstock powder copper composition. This thesis has demonstrated that all of the aluminum copper powders utilized can be successfully deposited via the low-pressure cold spray process with helium as the carrier gas. The copper content of the powders has a direct effect on the volume fraction of Al2Cu intermetallics, and on the coating hardness, while having no measurable effect on critical velocity for deposition or the coating thickness per pass.
Type
Thesis
Description
Series/Report No
Department
Mechanical and Aerospace Engineering
Mechanical and Aerospace Engineering (MAE)
Organization
Identifiers
NPS Report Number
Sponsors
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Format
Citation
Distribution Statement
Approved for public release; distribution is unlimited.
Rights
This publication is a work of the U.S. Government as defined in Title 17, United States Code, Section 101. Copyright protection is not available for this work in the United States.