A critical analysis of collision dynamics pertaining to aluminum micro particles on aluminium 6061 alloy substrate in cold spray additive manufacturing process

Cold spray (CS) is a form of additive manufacturing process, involving the accumulation ductile metal micro particles to create new surface coatings or free-standing structures. Metallic are accelerated through gas stream, experience high-strain-rate microscopic ballistic collisions against target substrate. It yields tremendous amounts kinetic energy from extreme plastic deformation and In this paper, dynamic behavior aluminium micro-particles during collision analysed using micro-ballistic method. Aluminum 6061 alloy particles, approximately 20 μm in diameter, impact rebound off aluminum substrate over broad range surrounding temperatures velocities. This, turn, can provide insight into underlying material science behind cold process.