About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Materials Processing Fundamentals: Towards Sustainable Process Modeling, Design, and Operation
|
| Presentation Title |
Recovery and Re-Use of Metal Feedstock Powder in Cold Spray Deposition: Reducing Material Waste Through Powder Reclamation |
| Author(s) |
Ashton Lyon, Kyle L. Tsaknopoulos, Danielle L. Cote |
| On-Site Speaker (Planned) |
Ashton Lyon |
| Abstract Scope |
With solid-state cold spray deposition being explored as a sustainable additive manufacturing solution, low material efficiency coupled with the high cost of refractory alloy feedstock powder presents a challenge to sustainability and cost effectiveness, since valuable undeposited powder is often discarded as waste. This work implements a simple cyclone dust collector to capture unbonded particles for re-use in the cold spray process, reducing critical material waste through powder reclamation and post-processing reconditioning treatments. Virgin, recovered, and treated powders are compared through microscopy, X-ray diffraction, particle morphology, chemical analysis, and nanomechanical testing, while deposits sprayed using varying blends of virgin and recovered powders are evaluated for porosity, microstructure, and mechanical properties. The introduction of powder recovery during cold spray deposition is shown to be an effective method for reclaiming material previously considered waste, enabling a substantial advancement in the sustainability of cold spray processing. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Powder Materials, Recycling and Secondary Recovery, |