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<p>Both laser thermal softening and in-situ micro-forging can effectively improve the microstructure and properties of cold-sprayed deposition layer. However, each process has its own limitations. In this study, laser thermal softening and in-situ micro forging were simultaneously introduced into cold spray process. The synergistic effects on the microstructure and mechanical properties of AA7075 deposits were examined. SEM, EBSD, and XRD were used to study the microstructure evolution of deposits in details. The results showed that, with 20wt.% alumina particles in the raw material powder, the optimal laser power for cold spray was approximately 1.8&#xa0;kW. At this point, the porosity of the deposits dropped to 0.1%, while the powder deposition efficiency slightly decreased (from 27.3% to 23.9%). The ultimate tensile strength (UTS) reached 292 ± 15&#xa0;MPa, and the elongation (EL) increased to 8.4 ± 1.1%. Compared to the deposits produced via in-situ micro-forging assisted cold spray solely, the UTS and the EL increased by approximately 59.5% and 58.5%, respectively. As the laser power increased, the initially increased and then decreased, and the local misorientation within the deposited layers significantly reduced. In addition, T6 heat treatment further eliminated defects in the deposited layer and enhanced its mechanical properties. The heat-treated 1.8&#xa0;kW deposits exhibited the highest UTS (446 ± 14&#xa0;MPa), while the EL slightly decreased to 7.1% ± 0.6%. The evidences verify that the synergistic effects of laser thermal softening and in-situ micro forging are feasible for improving the performance of cold sprayed AA7075 deposits.</p>

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The Synergistic Effects of Laser Thermal Softening and In-Situ Micro Forging on the Microstructure and Mechanical Properties of Cold Sprayed AA7075 Deposits

  • 期刊论文

  • 发表日期：

    2026年3月20日

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  • Yunhui Peng,
  • Kang Wang,
  • Xinyu Cui,
  • Tianying Xiong,
  • Zhipo Zhao,
  • Jiqiang Wang

摘要

Both laser thermal softening and in-situ micro-forging can effectively improve the microstructure and properties of cold-sprayed deposition layer. However, each process has its own limitations. In this study, laser thermal softening and in-situ micro forging were simultaneously introduced into cold spray process. The synergistic effects on the microstructure and mechanical properties of AA7075 deposits were examined. SEM, EBSD, and XRD were used to study the microstructure evolution of deposits in details. The results showed that, with 20wt.% alumina particles in the raw material powder, the optimal laser power for cold spray was approximately 1.8 kW. At this point, the porosity of the deposits dropped to 0.1%, while the powder deposition efficiency slightly decreased (from 27.3% to 23.9%). The ultimate tensile strength (UTS) reached 292 ± 15 MPa, and the elongation (EL) increased to 8.4 ± 1.1%. Compared to the deposits produced via in-situ micro-forging assisted cold spray solely, the UTS and the EL increased by approximately 59.5% and 58.5%, respectively. As the laser power increased, the initially increased and then decreased, and the local misorientation within the deposited layers significantly reduced. In addition, T6 heat treatment further eliminated defects in the deposited layer and enhanced its mechanical properties. The heat-treated 1.8 kW deposits exhibited the highest UTS (446 ± 14 MPa), while the EL slightly decreased to 7.1% ± 0.6%. The evidences verify that the synergistic effects of laser thermal softening and in-situ micro forging are feasible for improving the performance of cold sprayed AA7075 deposits.