High-performance bulk pure Al prepared through cold spray-friction stir processing composite additive manufacturing

A bulk pure Al sample was prepared through cold spray-friction stir processing composite additive manufacturing (CFAM). The microstructure is uniform, and consists of fine and equiaxed recrystallized grains with an average grain size of 4.4 μm. Continuous and discontinuous dynamic recrystallizations are primary recrystallization mechanisms. The ultimate tensile strength and elongation are 87 MPa and 60.3%, respectively, with the fracture mode being ductile. The order of contribution of strengthening mechanisms for the CFAM sample, from highest to lowest, is fine grain strengthening, dislocation strengthening, and grain orientation strengthening.