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The FeCuAl-Al2O3 coatings deposited by means of supersonic technique - microstructure and properties

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In the past few years it has been scientifically and technically demonstrated that the employment of nanostructured materials to produce high performance surfaces is a winning approach for creating coatings with exceptional properties: low friction, and high resistance to wear, temperature, and chemical attack [1÷3]. Advanced, multifunctional nanophased powder systems can be produced using high energy milling technology. This technology exploits mechano- chemical synthesis principles, and simultaneously manages to induce material property improvements such as a fine phase distribution and crystal size refinement [4]. It is necessary to adopt a deposition process which does not damage the nanostructure of starting milled materials (i.e. exposing them to high temperature for prolonged time) in order to take advantage of improved properties. In the coating sector, thermal spray technology is commonly used to produce high thickness coatings in the defense, aerospace and gas turbine industries [5÷7]. Particle velocity and particle temperature, together with substrate temperature, are the most important parameters affecting the deposit formation. Thus, the “Cold Gas Spraying" technology, which uses purely kinetic effects to deposit powders, fulfils the requirement of not damaging the nanostructure, even if it sometimes presents some technical limitations that need to be overcome[7÷9]. Various factors are responsible for the quality of the coating and it’s surface in terms of corrosion and wear resistance. Bonding between sprayed powder particles markedly affects the cohesion and mechanical properties of the coating. In the present study, FeCuAl-Al2O3 (FAC-Al) powder was used to prepare coatings by cold spray process. The aim of this work was to investigate the microstructure of the FeCuAl-Al2O3 coatings obtained by supersonic cold gas spraying of micropowder prepared by the high energy milling of the commercially availa[...]

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