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<p>This study investigates the structural repair of 6061 aluminum using cold spray deposition with nitrogen as the carrier gas, focusing on the effects of various post-spray treatments on microstructural integrity and mechanical performance. Notched aluminum plates were repaired via cold spray and subsequently subjected to conventional heat treatment and hot isostatic pressing at both standard and elevated temperatures. The efficacy of the repairs was evaluated through microstructural characterization and mechanical testing, including microhardness, tensile, three-point bending, and fatigue tests. Results showed that while the as-deposited condition showed poor interparticle bonding and weak interfacial adhesion, all post-spray treatments substantially improved the load-bearing capacity of the repaired specimens. Among these, elevated-temperature treatments resulted in superior mechanical properties due to enhanced interparticle cohesion and interfacial bonding. Fractographic analysis confirmed a transition in failure mode from interfacial delamination in standard-temperature-treated specimens to cohesive fracture within the cold spray deposits in high-temperature-treated samples.</p>

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Cold Spray Repair of 6061 Aluminum Using Nitrogen: Microstructural and Mechanical Characterization with Post-spray Heat Treatments

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年6月3日

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  • Ahmad Nourian,
  • Aidan Sevinsky,
  • Samuel Boese,
  • Chad Beamer,
  • Sinan Müftü

摘要

This study investigates the structural repair of 6061 aluminum using cold spray deposition with nitrogen as the carrier gas, focusing on the effects of various post-spray treatments on microstructural integrity and mechanical performance. Notched aluminum plates were repaired via cold spray and subsequently subjected to conventional heat treatment and hot isostatic pressing at both standard and elevated temperatures. The efficacy of the repairs was evaluated through microstructural characterization and mechanical testing, including microhardness, tensile, three-point bending, and fatigue tests. Results showed that while the as-deposited condition showed poor interparticle bonding and weak interfacial adhesion, all post-spray treatments substantially improved the load-bearing capacity of the repaired specimens. Among these, elevated-temperature treatments resulted in superior mechanical properties due to enhanced interparticle cohesion and interfacial bonding. Fractographic analysis confirmed a transition in failure mode from interfacial delamination in standard-temperature-treated specimens to cohesive fracture within the cold spray deposits in high-temperature-treated samples.