First Advisor
Chien Wern
Term of Graduation
January 2026
Date of Publication
6-1-2026
Document Type
Thesis
Language
English
Subjects
Additive Manufacturing, CMD Powders, Cold Spray, Nickel Aluminum Bronze
Physical Description
1 online resource ( pages)
Abstract
Nickel-aluminum bronze (NAB) is widely used for maritime components but is traditionally limited to casting due to its complex microstructure. Fine β′ phase formation in NAB is governed by the solid-state transformation of the high-temperature β phase during cooling. This ordered martensitic β′ forms via diffusionless transformation, contributing to brittleness. Conventional metal additive manufacturing (AM) techniques, such as Laser Powder Bed Fusion and Directed Energy Deposition, experience high in-process cooling rates that promote fine β′ formation, compromising mechanical performance. Powder production similarly suffers from β′ formation, often requiring additional processing. Cold Mechanically Derived (CMD) powders, produced from wrought feedstocks, retain many desirable properties of the wrought state and have recently gained commercial availability. C63000 NAB has been successfully produced in CMD form.Cold Spray Additive Manufacturing (CSAM) is a solid-state AM technique that accelerates powders through a supersonic nozzle, bonding particles via extreme plastic deformation. CSAM avoids high-temperature transformations, mitigating β′ formation and associated cracking. This work establishes a process window for C63000 NAB CMD powders in a nitrogen-based CSAM system, enabling industrial adoption. A 3×3×3 Design of Experiments was performed to evaluate the effects of spray temperature, pressure, and stand-off distance on as-sprayed density, targeting initial densities ≥90%. Temperature and pressure were identified as the dominant factors affecting density. Microstructure evaluation identified the subsequent material state and enabled direct comparison with a typical incoming wrought and CMD feedstock. By defining a CSAM process window for NAB, this study enables fabrication and repair of maritime components without casting and lays the foundation for future mechanical property and microstructure evaluation and industrial adoption.
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Recommended Citation
LaMont, Trent Matthew, "Process Development of C63000 Nickel Aluminum Bronze for Cold Spray" (2026). Dissertations and Theses. Paper 7129.