Devitrification-Induced Tailoring of Microstructure and Strength in Aluminum High-Entropy Alloy Powder for Cold Spray Deposition

The development of high-strength cold spray deposits using amorphous/nanocrystalline aluminum high-entropy alloy (Al HEA) powder is hindered by the lack of understanding of correlations between powder microstructure and its deformation behavior. In this study, gas-atomized Al HEA powder (Al 90.05 -Y...

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Bibliographic Details
Published in:Journal of thermal spray technology 2024-06, Vol.33 (5), p.1348-1364
Main Authors: John, Denny, Sousa, Bryer C., Paul, Tanaji, Mohammed, Sohail M. A. K, Cote, Danielle L., Agarwal, Arvind
Format: Article
Language:English
Subjects:
Analytical Chemistry
Characterization and Evaluation of Materials
Chemistry and Materials Science
Corrosion and Coatings
Machines
Manufacturing
Materials Science
Original Research Article
Processes
Surfaces and Interfaces
Thin Films
Tribology
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Summary:The development of high-strength cold spray deposits using amorphous/nanocrystalline aluminum high-entropy alloy (Al HEA) powder is hindered by the lack of understanding of correlations between powder microstructure and its deformation behavior. In this study, gas-atomized Al HEA powder (Al 90.05 -Y 4.4 -Ni 4.3 -Co 0.9 -Sc 0.35  at.%) is devitrified at 298, 345, 362, and 450 °C to optimize strength and deformation for cold spraying. Devitrification-induced atomic rearrangement developed equiaxed Al grains and Al 3 Ni and Al 3 Sc precipitates. The amorphous content, growth of grains, hard precipitates, and reduced dislocation density increased the hardness by 16% to 515 HV at 298 °C and decreased the hardness by 55% to 190 HV at 450 °C. The compressive strength of Al HEA powder increased by 5% to 1559 MPa at 298 °C and decreased by 49% to 760 MPa at 450 °C. To enhance the limited sprayability of Al HEA powder, compressive strength is used to model optimized cold spray process maps. Helium gas with temperatures from 300 to 800 °C and a pressure of 40 bar can produce cold spray deposits with deposition efficiency greater than 70%. The scientific insights acquired from the present study provide a gateway toward developing novel lightweight and high-strength aluminum alloy deposits, thus marking an advancement in cold spray technology.
ISSN:1059-9630
1544-1016
DOI:10.1007/s11666-024-01787-3