Menon, Vineeth2024-07-312024-07-312024-06https://unbscholar.lib.unb.ca/handle/1882/38071In this work, the high-energy mechanical alloying (HE-MA) method was used to manufacture nanostructured Ni(Zn)–Al2O3 composite particles, to be utilized as particle feedstock in cold spray additive manufacturing process. Pre-milled Ni(Zn) alloy precursors were milled in SPEXTM 8000 M high energy ball mill. Microstructural characterization with Electron backscatter diffraction (EBSD) studies and particle size distribution of Ni(Zn) alloy particles showed that, in comparison to Ni(10wt.%Zn) alloy particles, Ni(5wt.%Zn) experienced higher plastic deformation, work hardening, and fracture. Two design compositions (30-wt.% and 50-wt% α-alumina) were paired with two substitutional alloy compositions, Ni(5wt.%Zn) and Ni(10wt.%Zn), for the material design-of-experiment (DoE). The embedment of nanometer-sized α-alumina grains in micron-sized Ni(Zn) alloy matrix was confirmed via microstructural analysis. The composite particles that were milled for four hours had the desired particle size distribution to serve the purpose for cold spraying, according to the particle size measurement obtained via laser diffraction spectroscopy (LDS).x, 108electronicenhttp://purl.org/coar/access_right/c_abf2master thesisSaha, Gobinda C.Mechanical Engineering