Theses and Dissertations

Date of Award


Document Type


Degree Name

Master of Science (MS)


Mechanical Engineering

First Advisor

Dr. Javier A. Ortega

Second Advisor

Dr. Jianzhi Li

Third Advisor

Dr. Horacio Vasquez


Cold Spray Additive Manufacturing (CSAM) is a sub-category of thermal spray technology where a metal powder is accelerated in a gas stream toward a metal substrate at high velocities, producing a metallurgical bond with the metal substrate on impact. The present study investigates the effect of Al2O3 additions on the tribological properties of nickel-based cold spray coatings deposited on aluminum 6061 for aerospace and industrial manufacturing. The tribological performance of the nickel-based cold spray coatings with and without Al2O3 additions was evaluated using an abrasive wear test based on the ball-crater technique. In addition, the wear and friction characteristics of the CSAM coatings were evaluated with a pin-on-disk tribometer. It was found that the addition of Al2O3 particles did not provide any improvement in the tribological properties of the coating. However, the addition of alumina particles was highly effective in decreasing porosity in the coating.


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