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Acta Metallurgica Sinica (English Letters)  2019, Vol. 32 Issue (12): 1449-1458    DOI: 10.1007/s40195-019-00917-z
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Effects of Dissimilar Alumina Particulates on Microstructure and Properties of Cold-Sprayed Alumina/A380 Composite Coatings
Xiang Qiu1,2, Naeem ul Haq Tariq1,3,4, Lu Qi1,2, Jun-Rong Tang1,2, Xin-Yu Cui1, Hao Du1, Ji-Qiang Wang1(), Tian-Ying Xiong1()
1 Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
2 School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
3 University of Chinese Academy of Sciences, No. 19 (A) Yuquan Road, Shijingshan District, Beijing 100049, China
4 Department of Metallurgy and Materials Engineering, Institute of Engineering and Applied Sciences, Nilore, Islamabad, Pakistan
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In this study, alumina/A380 composite coatings were fabricated by cold spray. The influence of alumina particulates’ morphology (spherical and irregular) and content on the deposition behavior of the coatings (including surface roughness, surface residual stress, cross-sectional microstructure and microhardness) was investigated. Results revealed that the spherical alumina mainly shows micro-tamping effect during deposition, which result in remarkable low surface roughness and porosity of the coatings. In addition, very low deposition efficiency and good interfacial bonding between the coating and the substrate were achieved. For irregular alumina particles, the embedding of ceramic particulates in the coating was dominant during deposition process, resulting in high retention in the final deposit. However, it showed limited influence on porosity, surface roughness and interfacial bonding of the deposit. The coatings containing irregular alumina particulates exhibited much higher microhardness than those containing spherical alumina due to the higher load-bearing capacity of deposited alumina.

Key words:  Cold spray      Alumina particles      Microstructure      Micro-tamping effect      Embedding effect     
Received:  21 February 2019     

Cite this article: 

Xiang Qiu, Naeem ul Haq Tariq, Lu Qi, Jun-Rong Tang, Xin-Yu Cui, Hao Du, Ji-Qiang Wang, Tian-Ying Xiong. Effects of Dissimilar Alumina Particulates on Microstructure and Properties of Cold-Sprayed Alumina/A380 Composite Coatings. Acta Metallurgica Sinica (English Letters), 2019, 32(12): 1449-1458.

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Fig. 1  Residual stress measurement: a the detectors of the stress analyzer; b data analysis of detector 1; c data analysis of detector 2; d elliptical fitting of data from b and c
Fig. 2  Morphologies of a A380 powders; b S-Al2O3 powders; c I-Al2O3 powders; d particle size distributions
Fig. 3  a Laser confocal scanning microscope graphs of surface morphology; b average surface roughness of the coatings
Fig. 4  Representative cross-sectional SEM micrographs of a pure A380 deposits; b S-Coatings and c I-Coatings at different magnifications
Fig. 5  Porosity of the pure A380 and composite coatings
Fig. 6  Volume fraction of alumina deposited in the coatings as compared to the feedstock powder blend
Fig. 7  Surface residual stresses of the coatings
Fig. 8  Representative SEM images of the indentation of a pure A380 deposits; b S-Coatings and c I-Coatings; d the microhardness values of coatings
Fig. 9  Schematic diagrams of deposition behavior for S- and I-alumina coatings
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