LAUSR

Abstract The dynamic elastic behavior of cold sprayed aluminum 6061 coatings is analyzed to understand the inherent role of in-situ splat sintering from ambient to 400 °C for air and helium sprayed coatings. Higher surface energy and lower flattening ratio of air sprayed coating in as-sprayed condition result in 28% densification during splat sintering compared to 15% in heat-treated helium sprayed ones. Elastic modulus and damping behavior can be divided into three distinct temperature regimes based on sintering and progressive inter-splat structure. A theoretical analysis is established, which shows that normalized elastic modulus is an exponential function of the inter-splat porosity. This study establishes the correlation between inter-splat thermal phenomena and coating's dynamic mechanical properties at elevated temperatures.