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<p>Current additive manufacturing methods for joining and fabricating shape memory alloy (SMA) components cause heat affected zones that alter nitinol’s original properties and limit large-scale application of nitinol (NiTi) parts. This work examines the feasibility of using solid-state cold spray additive manufacturing to join SMA NiTi to similar and dissimilar materials. Ni<sub>50.3</sub>Ti at.% feedstock NiTi powders were optimized for deposition thickness on SMA substrates while retaining their base nanohardness of 4.74 ± 1.15 GPa by varying cold spray processing parameters; 2-mm thick consolidations were achieved with high powder feeder rates and slower raster speeds around 10–25&#xa0;mm/s with 40 raster passes. These optimized parameters guided fabrication of application-driven SMA components: lap joints, nested tubes, and NiTi wire fasteners created with SMA NiTi and Al 6061 feedstocks/substrates. In all components, failure occurred at the SMA NiTi consolidation interface, rather than within the powder deposit as in the case of the Al 6061 components. Further optimization is needed before these components can replace those joined with traditional fusion methods, but the results highlight the potential application of cold spray processing to join SMA materials and structural components while retaining base feedstock properties.</p>

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Fabricating Application-Driven SMA NiTi Components Using Optimized Cold Spray Additive Manufacturing Parameters

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年4月20日

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  • Eva R. Piazza,
  • Ashton Lyon,
  • Matthew Gleason,
  • Kyle Tsaknopoulos,
  • Danielle L. Cote

摘要

Current additive manufacturing methods for joining and fabricating shape memory alloy (SMA) components cause heat affected zones that alter nitinol’s original properties and limit large-scale application of nitinol (NiTi) parts. This work examines the feasibility of using solid-state cold spray additive manufacturing to join SMA NiTi to similar and dissimilar materials. Ni50.3Ti at.% feedstock NiTi powders were optimized for deposition thickness on SMA substrates while retaining their base nanohardness of 4.74 ± 1.15 GPa by varying cold spray processing parameters; 2-mm thick consolidations were achieved with high powder feeder rates and slower raster speeds around 10–25 mm/s with 40 raster passes. These optimized parameters guided fabrication of application-driven SMA components: lap joints, nested tubes, and NiTi wire fasteners created with SMA NiTi and Al 6061 feedstocks/substrates. In all components, failure occurred at the SMA NiTi consolidation interface, rather than within the powder deposit as in the case of the Al 6061 components. Further optimization is needed before these components can replace those joined with traditional fusion methods, but the results highlight the potential application of cold spray processing to join SMA materials and structural components while retaining base feedstock properties.