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. Murat Tiryakioğlu

Third Advisor

Dr. Stephen Stagon

Department Chair

Dr. Osama Jadaan

College Dean

Dr. William F. Klostermeyer


The Cold-Gas Dynamic-Spray process also known as Cold Spray (CS) has been researched for three decades. The CS process is a solid-state deposition technique via supersonic velocity of powder particles at a temperature significantly below the melting point of the spray material. This thesis presents background on the overall CS process parameters, and additional information on the microstructural and mechanical properties of typical Cold Sprayed materials.This Thesis primarily presents a study on the microstructural annealing response of CS Al 6061. It should be noted that for this study, the term “annealing” is used in the sense of the classical metallurgical definition of annealing, and not a specific temper designation for the 6061 alloy. Cross sections of CS Al 6061 were imaged with a scanning electron microscope (SEM) in secondary electron (SE), backscatter electron (BSE), and electron backscatter diffraction (EBSD) imaging mode for quantitative and qualitative information on the grain size and orientation of the CS microstructure. The detailed SE, BSE and EBSD mode images present the grain size and grain orientation of the original powder, as received (AR) state and after heat treating at 200°C for 1 hour, 10 hours, and 100 hours. Three different regions, characterized with distinctly differing microstructures, are labeled as low, medium, and high deformation regions, and their microstructures, and evolving features are discussed. Vickers microhardness testing are performed to examine the differences in hardness values between different heat treatments, and for correlation with the level of deformation and grain refinement in the microstructure. SEM imaging was used in BSE mode to correlate microhardness variation to the different regions within the CS microstructure.