Cold Spray in Powder Metallurgy for Nickel Aluminium Bronze Production

Researchers from SPEE3D, based in Melbourne, Australia, and Charles Darwin University (CDU) in Darwin, published a study in PLOS One. The study examines the use of Cold Spray Additive Manufacturing (AM) for producing Nickel Aluminium Bronze (NAB) alloys. It compares this method to traditional Powder Metallurgy (PM) techniques, highlighting its potential for producing high-performance materials more efficiently.

The study focused on both binary Aluminium Bronze (AB) and NAB alloys. The AB alloy contained 9.9% aluminium alloy (Al6061) powder and copper powder. The NAB alloy included 11% Al6061 powder, 5.8% nickel powder, 6.8% iron powder, and copper powder. The powders were mixed in controlled conditions and deposited using a LightSPEE3D AM machine with compressed air. After deposition, heat treatments, including homogenization, aging, and Hot Isostatic Pressing (HIP), enhanced the material properties.

Cold Spray Additive Manufacturing: A Better Alternative

The results showed that Cold Spray AM, combined with heat treatments, produced NAB alloys with desirable microstructures. The alloys exhibited fine κ phases and mechanical properties, such as a yield strength above 280 MPa, tensile strength above 500 MPa, and 20% elongation. These results are comparable to traditional casting methods, which produce 240 MPa yield strength, 580 MPa tensile strength, and 15% elongation. However, Cold Spray AM outperformed traditional PM methods in mechanical properties.

The study also found that replacing solution treatment with the HIP process at 1035°C further enhanced the mechanical properties of NAB samples. This makes Cold Spray AM a promising alternative to traditional casting and PM methods for producing high-performance NAB materials.

Researchers suggest that Cold Spray AM is more efficient and scalable for producing advanced alloys. Its applications extend to industries that require high-strength materials, such as aerospace and defense. By using Cold Spray technology, manufacturers can produce durable, reliable components while reducing material waste and processing time.