Key role of temperature on delamination in solid-state additive manufacturing via supersonic impact

Cold spray (CS) has emerged as a representative of solid-state additive manufacturing (AM) via supersonic impact. It enables a high deposition rate of solid-state microparticles. Delamination, however, tends to occur when depositing too thick; this remains to be conquered. Here, a CS-like process, warm spray (WS), was presented. Interestingly, it was found that the appropriate increase in particle temperature can effectively reduce the residual stress amplitude, relieving the concentrated tensile stress and safeguarding the additively manufactured components from interfacial delamination even when depositing too thick. The key role of temperature on delamination was identified in solid-state AM via supersonic impact. GRAPHICAL ABSTRACT IMPACT STATEMENT It makes a clear understanding of the delamination issue in solid-state AM via supersonic impact, providing scientific guidance for technological/equipment upgrading and safeguarding the structural integrity of complex, large-size components.