Non-equilibrium alloy cold spray feedstock powders, manufacturing processes utilizing the same, and articles produced thereby

A method, comprising:

• forming a molten alloy into a solid Non-Equilibrium Alloy (NEA) body utilizing a casting process having a cooling rate equal to or greater than approximately 1×106 degrees Celsius per second;
• mechanically converting the solid NEA body into a NEA feedstock powder;
• and
• subjecting the feedstock powder to an anneal processing having a maximum anneal temperature (TANNEAL_MAX);
• wherein the NEA feedstock powder comprises an alloy matrix throughout which a first minority constituent is dispersed;
• wherein the first minority constituent precipitates from the alloy matrix when the NEA feedstock powder is exposed to temperatures exceeding a critical temperature threshold TCRITICAL for a predetermined time period;
• and
• wherein TCRITICAL is less than a melt point of the NEA feedstock powder and greater than TANNEAL_MAX.

A method, comprising:

• utilizing an Additive Manufacturing (AM) cold spray process to fabricate a near-net article from a Non-Equilibrium Alloy (NEA) feedstock powder having a melt point (TALLOY_MP), the NEA feedstock powder comprising:
• an aluminum alloy matrix;
• and
• a non-trace amount of silicon contained in the aluminum alloy matrix and precipitating therefrom when the NEA feedstock powder is exposed to temperatures exceeding a critical temperature threshold (TCRITICAL) for a predetermined time period;
• after utilizing the AM cold spray process to fabricate the near-net article from a NEA feedstock powder, annealing the near-net article at a maximum annealing temperature (TANNEAL);
• wherein the steps of utilizing and annealing are performed such that TANNEAL<TCRITICAL<TALLOY_MP.