EFFECT OF Ti6Al4V COLD SPRAYING ON THE SURFACE QUALITY OF ADDITIVELY MANUFACTURED AlSi10Mg ALLOY

İbrahim Can Duman; Dursun Meriç; Hasan Gedikli; Remzi Ecmel Ece; Ömer Necati Cora

doi:10.70858/tijmet.1821472

EFFECT OF Ti6Al4V COLD SPRAYING ON THE SURFACE QUALITY OF ADDITIVELY MANUFACTURED AlSi10Mg ALLOY

Abstract

Additive manufacturing (AM) has emerged as a transformative production technology, enabling the fabrication of complex geometries and customized components, particularly in industries such as aerospace, defense, biomedical, automotive, and energy. The design flexibility offered by AM provides significant advantages, especially in producing intricate structures that are difficult to achieve using conventional manufacturing methods. Among AM-compatible materials, AlSi10Mg alloy stands out due to its high specific strength, excellent thermal and electrical conductivity, and low density. However, the layer-by-layer nature of Laser Powder Bed Fusion (L-PBF) often results in poor surface quality and insufficient mechanical properties. Therefore, post-processing methods are essential to enhance the surface integrity of AM-produced parts. In this study, the cold spraying (CS) process was applied to improve the surface properties of AlSi10Mg samples manufactured by the L-PBF technique. The samples 100x50x5 mm3 in dimensions were fabricated using Aconity MIDI L-PBF machine and characterized using optical microscopy and a non-contact profilometer. Subsequently, Ti6Al4V powders (15–53 µm in diameter) were deposited onto the samples using a cold spray system under the following process parameters: air temperature of 460 °C, air pressure of 7 bar, powder feed rate of 24.9 g/min, and nozzle distance of 5 mm. The spraying process was performed at three different traverse speeds (10, 20, and 30 mm/s) to examine the influence on surface roughness. In the continuation of the study, post-spray surface measurements were taken and compared with the measurements obtained in AM part production.

Keywords

Additive Manufacturing (AM) , Laser Powder Bed Fusion (L-PBF) , Cold Spraying (CS) , Surface Characterization , Post-processing

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Details

Primary Language

English

Subjects

Material Design and Behaviors , Composite and Hybrid Materials , Material Characterization , Material Production Technologies

Journal Section

Research Article

Authors

İbrahim Can Duman ^*
0000-0001-6466-0129
Türkiye

Dursun Meriç
0000-0001-7702-2708
Türkiye

Hasan Gedikli
0000-0003-0429-9065
Türkiye

Remzi Ecmel Ece
0000-0002-8797-4224
Türkiye

Ömer Necati Cora
0000-0003-3564-5493
Türkiye

Publication Date

December 31, 2025

Submission Date

November 11, 2025

Acceptance Date

December 27, 2025

Published in Issue

Year 2025 Volume: 8 Number: 2

DOI

https://doi.org/10.70858/tijmet.1821472

IZ

https://izlik.org/JA48KC78UB

APA

Duman, İ. C., Meriç, D., Gedikli, H., Ece, R. E., & Cora, Ö. N. (2025). EFFECT OF Ti6Al4V COLD SPRAYING ON THE SURFACE QUALITY OF ADDITIVELY MANUFACTURED AlSi10Mg ALLOY. The International Journal of Materials and Engineering Technology, 8(2), 67-73. https://doi.org/10.70858/tijmet.1821472

Bu eser Creative Commons Atıf-GayriTicari 4.0 Uluslararası Lisansı ile lisanslanmıştır.

EFFECT OF Ti6Al4V COLD SPRAYING ON THE SURFACE QUALITY OF ADDITIVELY MANUFACTURED AlSi10Mg ALLOY

Abstract

Keywords

References

Details

Primary Language

Subjects

Journal Section

Authors

Publication Date

Submission Date

Acceptance Date

Published in Issue

DOI

IZ

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