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Room Temperature Deformation Mechanisms of Alumina Particles Observed from In Situ Micro-compression and Atomistic Simulations

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Abstract

Aerosol deposition (AD) is a solid-state deposition technology that has been developed to fabricate ceramic coatings nominally at room temperature. Sub-micron ceramic particles accelerated by pressurized gas impact, deform, and consolidate on substrates under vacuum. Ceramic particle consolidation in AD coatings is highly dependent on particle deformation and bonding; these behaviors are not well understood. In this work, atomistic simulations and in situ micro-compressions in the scanning electron microscope, and the transmission electron microscope (TEM) were utilized to investigate fundamental mechanisms responsible for plastic deformation/fracture of particles under applied compression. Results showed that highly defective micron-sized alumina particles, initially containing numerous dislocations or a grain boundary, exhibited no observable shape change before fracture/fragmentation. Simulations and experimental results indicated that particles containing a grain boundary only accommodate low strain energy per unit volume before crack nucleation and propagation. In contrast, nearly defect-free, sub-micron, single crystal alumina particles exhibited plastic deformation and fracture without fragmentation. Dislocation nucleation/motion, significant plastic deformation, and shape change were observed. Simulation and TEM in situ micro-compression results indicated that nearly defect-free particles accommodate high strain energy per unit volume associated with dislocation plasticity before fracture. The identified deformation mechanisms provide insight into feedstock design for AD.

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Notes

  1. It is believed that the order of magnitude difference in compression rate is not large enough to introduce substantial effects. Experimental measurements from large particle #1 (LP1), subjected to the higher compression rate of 0.03 s-1 were in-line with values from other large particles.

  2. Here we use the term “fracture” in a general sense. It is unclear whether the observed event was truly fracture (i.e., no atomic bonds) as opposed to amorphization or crystallographic rotation in the center of the particles. Analysis showed the stress parallel to the compression axis at the center of both NPs decreased shortly after void nucleation, suggesting that subsequent fracture may have occurred and relieved the stress.

  3. The displacement bursts with apparent constant loads are a result of the control system failing to keep up with the rapidly collapsing particle, although these SEM micro-compression tests were performed in displacement control mode.

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Acknowledgments

B.L. Boyce, K. Hattar, and D.C. Bufford were supported by the Department of Energy (DOE) office of Basic Energy Sciences, Materials Science and Engineering. The authors acknowledge Sumitomo Chemical Co., LTD for supplying the alumina particles. We are grateful to C.B. Carter, P. Clem, D. Hirschfeld, H. Brown-Shaklee, R.D. Murphy, R. Tandon, and E.D. Reedy for valuable discussions. This work was performed, in part, at the Center for Integrated Nanotechnologies (CINT), an Office of Science User Facility operated for the U.S. DOE Office of Science. This work is supported by the Laboratory Directed Research and Development program at Sandia National Laboratories, a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. DOE’s National Nuclear Security Administration under contract DE-AC04-94AL85000.

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Authors and Affiliations

  1. Sandia National Laboratories, Albuquerque, NM, USA

    Pylin Sarobol, Michael Chandross, Jay D. Carroll, William M. Mook, Daniel C. Bufford, Brad L. Boyce, Khalid Hattar, Paul G. Kotula & Aaron C. Hall

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  1. Pylin Sarobol
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Correspondence to Pylin Sarobol.

Additional information

This article is an invited paper selected from presentations at the 2015 International Thermal Spray Conference, held May 11-14, 2015, in Long Beach, California, USA, and has been expanded from the original presentation.

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Sarobol, P., Chandross, M., Carroll, J.D. et al. Room Temperature Deformation Mechanisms of Alumina Particles Observed from In Situ Micro-compression and Atomistic Simulations. J Therm Spray Tech 25, 82–93 (2016). https://doi.org/10.1007/s11666-015-0295-2

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