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Optimization Of Porosity In Cold Spray Produced Copper And Zinc Coatings, Cameron Hughes

Graduate Theses & Non-Theses

Since its invention in 1981, the cold spray (CS) additive manufacturing (AM) process has been studied and optimized to produce well-adhered, dense material coatings. CS can operate at a wide range of temperatures if the feed material remains in a solid state. Copper and zinc were studied to characterize and understand the effects of heating element voltage, travel speed, and standoff distance on deposit porosity, grain size, microhardness, and coating thickness. Samples were sprayed on 3.2 mm x 25 mm x 150 mm 6061 aluminum substrates. Sections were taken from the middle of the samples to represent steady-state conditions. Sample …