Process optimisation of cold spray additive manufacturing of FeCoNiCrMn high-entropy alloy

The deposition window of cold spray additive manufacturing (CSAM) a high-entropy alloy (HEA) was optimised by investigating processing parameters on deposition efficiency and porosity. The optimal parameters were obtained with helium as the driving gas, gas inlet temperature was at 700°C, and spray distance at 25 mm, at which the deposit was the thickest and of the lowest porosity. The type of driving gas is critical as it affects the porosity and deposition efficiency, and helium is required to obtain high-quality HEA deposits. With it, gas inlet temperature and spray distance have a minimal effect. Furthermore, higher gas temperature and moderate spraying distance were selected to increase particle deformation and reduce the effect of shock waves at the plate front.