| About this Abstract |
| Meeting |
2025 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advances in Materials Deposition by Cold Spray and Related Technologies
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| Presentation Title |
Fatigue Resistance of Aluminum Alloy Components Repaired Using Cold Spray
|
| Author(s) |
Patrick Morrison, Krzysztof S. Stopka, John Ferguson, Michael Sangid |
| On-Site Speaker (Planned) |
Krzysztof S. Stopka |
| Abstract Scope |
Cold spray is a promising method for repairing high-value components, but its damage tolerance and durability behavior must first be evaluated. This talk focuses on evaluating the fatigue behavior of helium-sprayed AA6061 applied to an A356-T6 cast substrate compared to the same specimen geometry made entirely of the A356-T6 material. Fatigue testing was conducted using a marker band schedule to analyze fatigue crack growth rates in both materials. A Monte Carlo approach was subsequently used to incorporate experimental uncertainties into a crack growth model, probabilistically assessing reliability. The results indicate that the AA6061 cold spray material exhibited faster crack growth, reducing life by 25% compared to A356-T6. Despite this, the cost-effectiveness of cold spray makes it a viable repair method, with the caveats that the residual life is expected to be less than the pristine substrate material and the cold spray interface is prone to delamination during crack impingement. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Aluminum, Mechanical Properties |