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Machinability of Al 6061 Deposited with Cold Spray Additive Manufacturing

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Abstract

Additive manufacturing techniques such as cold spray are translating from research laboratories into more mainstream high-end production systems. Similar to many additive processes, finishing still depends on removal processes. This research presents the results from investigations into aspects of the machinability of aluminum 6061 tubes manufactured with cold spray. Through the analysis of cutting forces and observations on chip formation and surface morphology, the effect of cutting speed, feed rate, and heat treatment was quantified, for both cold-sprayed and bulk aluminum 6061. High-speed video of chip formation shows changes in chip form for varying material and heat treatment, which is supported by the force data and quantitative imaging of the machined surface. The results shown in this paper demonstrate that parameters involved in cold spray directly impact on machinability and therefore have implications for machining parameters and strategy.

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Authors and Affiliations

  1. Department of Mechanical and Manufacturing Engineering, Trinity College Dublin, Parsons Building, Dublin 2, Ireland

    Barry Aldwell, Garret E. O’Donnell & Rocco Lupoi

  2. Moog Dublin, 15 Northwest Business Park, Ballycoolin, Dublin 15, Ireland

    Elaine Kelly & Ronan Wall

  3. European Space Research and Technology Centre (ESTEC), European Space Agency, Keplerlaan 1, 2201 AZ, Noordwijk, The Netherlands

    Andrea Amaldi

Authors
  1. Barry Aldwell
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  2. Elaine Kelly
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  3. Ronan Wall
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  4. Andrea Amaldi
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  5. Garret E. O’Donnell
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  6. Rocco Lupoi
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Correspondence to Rocco Lupoi.

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Aldwell, B., Kelly, E., Wall, R. et al. Machinability of Al 6061 Deposited with Cold Spray Additive Manufacturing. J Therm Spray Tech 26, 1573–1584 (2017). https://doi.org/10.1007/s11666-017-0586-x

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  • DOI: https://doi.org/10.1007/s11666-017-0586-x

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