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Consolidation of Al2O3/Al Nanocomposite Powder by Cold Spray

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Abstract

While the improvement in mechanical properties of nanocomposites makes them attractive materials for structural applications, their processing still presents significant challenges. In this article, cold spray was used to consolidate milled Al and Al2O3/Al nanocomposite powders as well as the initial unmilled and unreinforced Al powder. The microstructure and nanohardness of the feedstock powders as well as those of the resulting coatings were compared. The results show that the large increase in hardness of the Al powder after mechanical milling is preserved after cold spraying. Good quality coating with low porosity is obtained from milled Al. However, the addition of Al2O3 to the Al powder during milling decreases the powder and coating nanohardness. This lower hardness is attributed to non-optimized milling parameters leading to cracked particles with insufficient Al2O3 embedding in Al. The coating produced from the milled Al2O3/Al mixture also showed lower particle cohesion and higher amount of porosity.

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Authors and Affiliations

  1. Industrial Materials Institute, National Research Council of Canada, Boucherville, J4B 6Y4, Canada

    Dominique Poirier & Jean-Gabriel Legoux

  2. Engineering and Computer Science, Concordia University, Montreal, H3G 2W1, Canada

    Robin A. L. Drew

  3. Mining and Materials Engineering, McGill University, Montreal, H3A 2B2, Canada

    Raynald Gauvin

Authors
  1. Dominique Poirier
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  2. Jean-Gabriel Legoux
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  3. Robin A. L. Drew
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  4. Raynald Gauvin
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Corresponding author

Correspondence to Dominique Poirier.

Additional information

This article is an invited paper selected from presentations at the 2010 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray: Global Solutions for Future Applications, Proceedings of the 2010 International Thermal Spray Conference, Singapore, May 3-5, 2010, Basil R. Marple, Arvind Agarwal, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2011.

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Poirier, D., Legoux, JG., Drew, R.A.L. et al. Consolidation of Al2O3/Al Nanocomposite Powder by Cold Spray. J Therm Spray Tech 20, 275–284 (2011). https://doi.org/10.1007/s11666-010-9595-8

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  • DOI: https://doi.org/10.1007/s11666-010-9595-8

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