NON-EQUILIBRIUM ALLOY COLD SPRAY FEEDSTOCK POWDERS, MANUFACTURING PROCESSES UTILIZING THE SAME, AND ARTICLES PRODUCED THEREBY

Methods (10) for producing Non-Equilibrium Alloy (NEA) feedstock powders (42, 50) are disclosed, as are methods (10) for fabricating articles from such NEA feedstock powders utilizing Additive Manufacturing (AM) cold spray processes. In various embodiments, the method (10) includes the step or process obtaining (24) an NEA feedstock powder (42, 50), which is composed of an alloy matrix throughout which a first minority constituent is dispersed. The first minority constituent precipitates from the alloy matrix when the NEA feedstock powder (42, 50) is exposed to temperatures exceeding a critical temperature threshold (T) for a predetermined time period. An AM cold spray process (18) is carried-out to produce a near-net article (68) from the NEA feedstock powder (42, 50), which is exposed to a maximum temperature (T) during the cold spray process. The near-net article (68) is then further processed (26) to yield a finished article. To substantially preserve the non-equilibrium state of the feedstock powder, Tis maintained below Tthrough the cold spray process.