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Cold spray is a solid-state powder-based additive manufacturingAdditive manufacturing technique. In this study, two brittle materials, Nd–Fe–B and Bi–Ti powders, were successfully consolidated using a low-pressure cold spray technique that requires a tailored-feedstock particle size distributionParticle Size Distribution. Feedstock materials were ball milled to achieve a particle size distributionParticle Size Distribution between 0.1 and 30 μm. The fine particles presumably improved inter-particle bonding and interlocking between the larger particles which enabled dense bulk material formation. This study details the first reported values of hardnessHardness, elemental mapping, and Cu-anode X-ray diffraction for tailored-feedstock low-pressure cold spray of Nd–Fe–B and Bi–Te. The as-deposited Nd–Fe–B sample exhibited a hardnessHardness of 256 ± 33 HV2.5 and Bi–Te’s measured 62 ± 23 HV1. Both samples contained multiple crystal phases beyond the expected Nd2Fe14B phase and Bi2Te3 phase. Consequently, the Nd–Fe–B sample showed significant magnetic softeningCold-spray compared to the feedstock powder.

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Evaluation of Additively Manufactured Nd–Fe–B and Bi–Te via Tailored-Feedstock Low-Pressure Cold Spray

  • 会议论文

  • 发表日期：

    2025年

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  • Thomas Keller,
  • Quinn Campbell,
  • Sam Boese,
  • Ogheneyunume Fitchorova,
  • Jack Lesko,
  • Andrew Neils

摘要

Cold spray is a solid-state powder-based additive manufacturingAdditive manufacturing technique. In this study, two brittle materials, Nd–Fe–B and Bi–Ti powders, were successfully consolidated using a low-pressure cold spray technique that requires a tailored-feedstock particle size distributionParticle Size Distribution. Feedstock materials were ball milled to achieve a particle size distributionParticle Size Distribution between 0.1 and 30 μm. The fine particles presumably improved inter-particle bonding and interlocking between the larger particles which enabled dense bulk material formation. This study details the first reported values of hardnessHardness, elemental mapping, and Cu-anode X-ray diffraction for tailored-feedstock low-pressure cold spray of Nd–Fe–B and Bi–Te. The as-deposited Nd–Fe–B sample exhibited a hardnessHardness of 256 ± 33 HV2.5 and Bi–Te’s measured 62 ± 23 HV1. Both samples contained multiple crystal phases beyond the expected Nd2Fe14B phase and Bi2Te3 phase. Consequently, the Nd–Fe–B sample showed significant magnetic softeningCold-spray compared to the feedstock powder.