Paper Type

Master's Thesis


College of Computing, Engineering & Construction

Degree Name

Master of Science in Mechanical Engineering (MSME)



NACO controlled Corporate Body

University of North Florida. School of Engineering

First Advisor

Dr. Paul Eason

Second Advisor

Dr. Stephen Stagon

Third Advisor

Dr. Grant Bevill

Department Chair

Dr. Alan Harris

College Dean

Dr. William Klostermeyer


This project employs multi-instrument materials characterization to analyze material made with the “Cold Spray” additive manufacturing process. Cold spray is an emerging additive manufacturing technique with unique benefits resulting from its low temperature adhesion process induced by plastic deformation. Metallic powder collides at high speeds creating three dimensional materials and coatings without the need for melting. Copper cold sprayed specimens were analyzed using a series of imaging techniques to characterize the microstructure at varying levels of detail and magnification. Scanning electron microscopy and electron back scattered diffraction were paired with microhardness testing to generate a correlative comparison between microstructure and physical properties of cold sprayed material. This research investigates how microhardness changes across the surface of highly deformed cold sprayed materials and the role inhomogeneous plastic deformation plays in level of microhardness. Both sprayed and transverse orientations were investigated providing a better understanding of the anisotropic mechanical properties created by the cold spray process. Results demonstrated that the cold sprayed microstructure exhibits an increase in microhardness with increasing levels of grain refinement in the sprayed orientation. This correlation was less apparent in the transverse orientation which reinforces the documented evidence that shows as-sprayed cold sprayed materials possess both anisotropic microstructure and properties.