Enhancing Coating Performance: Cold Spray of Al-Alloy with Quasicrystal Reinforcement

Description

Cold spray technology presents a novel and powerful method for producing high-performance composite coatings by depositing powder particles at supersonic velocities. Understanding the intricate interactions during coating formation due to the high kinetic energy impact of particles on the substrate and previously deposited particles, whether similar or dissimilar, is essential for defining coating properties in industrial applications. This knowledge not only allows for the optimization of process parameters to tailor composite properties but also ensures quality and reliability in cold spray applications. Our previous work on high-pressure cold spraying (HPCS) of Al-alloy (AA6061) reinforced by quasicrystals (QC) demonstrated a practical approach to forming functional composite coatings. These reinforced coatings could possess multiple properties that are challenging to obtain from individual matrices. This study also aims to validate the structural integrity of the composite coatings via scratch testing and cavitation using an ultrasonic vibratory testing device conducted on the composites and their HPCS-AA6061 counterparts. Microstructural characterization with scanning and transmission electron microscopes provided insights into coating details. We also investigated the deposition mechanism of Al-QC composite structures on softer Al-based and harder Fe-based substrates through a "wipe-test" method, simply referring to the rapid movement of the cold spray nozzle for particle deposition. Various deposition scenarios are discussed based on topographical features correlated with cross-sectional features, adherence, and coherence of particles in the composite structure. HPCS QC-reinforced composite coatings exhibited increased scratch resistance and higher interparticle cohesion (proportional to QC content) compared to their counterparts. Notably, the retention of QC particles in the composite structure as the reinforcing phase was observed. These findings highlight the robustness and flexibility of cold spraying in generating novel, integrated, and high-quality QC-reinforced composite coatings.

Aikajakso	6 kesäk. 2024
Tapahtuman otsikko	Les Rencontres Internationales de la Projection Thermique
Tapahtuman tyyppi	Conference
Sijainti	Jülich, SaksaNäytä kartalla
Tunnustuksen arvo	International