Leonardo Ajdelsztajn

Oxidation behavior of HVOF sprayed nanocrystalline NiCrAlY powder

Abstract This paper describes recent progress on the research into improving the oxidation behavior of the bond coat using a HVOF nanostructured NiCrAlY coating. Commercially available NiCrAlY powder was mechanically cryomilled and HVOF sprayed onto Ni-based alloy to form a nanocrystalline bond coat. The powder and coating structure were characterized by XRD, SEM, and TEM. Oxidation experiments were performed on the coating to form the thermally grown oxide layer (TGO). After heat treatment at 1000 °C for 24 and 95 h, a homogeneous α-Al2O3 layer was formed on top of the bond coat. The oxide layer was analyzed and compared to the coating sprayed using the as-received powder. As shown in the results, the nanostructured characteristic of the coating and the presence of Al2O3 within the cryomilled powders (oxidation occurred during cryomilling process) seem to affect the nucleation of the alumina layer on the top of the coating. The formation of a continuous TGO layer protects the coating from further oxidation and avoids the formation of mixed oxide protrusions, such as those presented in the coating sprayed using the as-received powder.

Bulk nanocrystalline aluminum 5083 alloy fabricated by a novel technique: Cryomilling and spark plasma sintering

Dense, bulk nanocrystalline aluminum 5083 alloy was fabricatedvia a combined technique: cryomilling (mechanical milling at cryogenic temperature) to achieve the nanocrystalline Al 5083 powder and spark plasma sintering (SPS) to consolidate the cryomilled powder. The results of X-ray diffraction analysis indicate that the average grain size in the SPS consolidated material is 51 nm, one of the smallest grain sizes ever reported in bulk Al alloys produced by powder metallurgy derived methods. In contrast, transmission electron microscopy (TEM) analysis revealed a bimodal grain size distribution, with an average grain size of 47 nm in the fine-grained regions and approximately 300 nm in the coarse-grained regions. Nanoindentation was used to evaluate the mechanical properties and the uniformity of the consolidated nanocrystalline Al 5083. The hardness of the material is greatly improved over that of the conventional equivalent, due to the fine grain size. The mechanisms for spark plasma sintering and the microstructural evolution are discussed on the basis of the experimental findings.

Cold gas dynamic spraying of iron-base amorphous alloy

This paper describes recent efforts to synthesize iron-base amorphous alloys coatings using cold gas dynamic spraying. Characterization of the gas-atomized iron-base (Fe-Cr-Mo-W-C-Mn-Si-Zr-B) powder shows that the powder is fully amorphous when the particle diameter is below 20 µm. The coatings produced were composed of the same microstructure as the one observed in the feedstock powder. The overall deformation suggests the occurrence of a localized deformation process at the particle/particle boundary and a possible adiabatic deformation softening inside the powder particles during splat formation. The synthesis of fully amorphous, porous-free coatings using cold gas dynamic spraying was demonstrated in this work.

Influence of Cryomilling on the Morphology and Composition of the Oxide Scales Formed on HVOF CoNiCrAlY Coatings

Commercially available, gas-atomized CoNiCrAlY powder was cryomilled to produce powder with nanocrystalline grains. The cryomilled powder and conventional gas-atomized powder were thermally sprayed using the HVOF process to prepare two coatings with fine-grain (∼15 nm) and coarse-grain (∼1 μm) microstructure, respectively. The two coatings were isothermally oxidized in air at 1000° C for up to 330 hr. The morphology and composition of the oxide scales formed on the two coatings were compared with each other. The results indicate that, while a fine-grain microstructure can promote the formation of a pure alumina layer on the coating by increasing the Al diffusion rate toward the surface, it can also accelerate the Al depletion by increasing the Al diffusion rate toward the substrate, which results in the formation of non-alumina oxides after long-term oxidation. The mechanisms governing the oxide formation are discussed in terms of atomic diffusion and thermodynamic stability.

Substrate roughness and thickness effects on cold spray nanocrystalline Al−Mg coatings

Nanocrystalline Al−Mg coatings were produced using the cold gas dynamic-spraying technique. Unsieved Al−Mg powder of average nanocrystalline grain size in the range of 10 to 30 nm and with a particle size distribution from 10 to >100 μm was used as the feedstock powder. The resulting coatings were evaluated using scanning electron microscopy (SEM), transmission electron microscopy, as well as microhardness and nanoindentation measurements. Coating observations suggest that the wide particle size distribution of the feedstock powder has a detrimental effect on the coating quality but that it can be successfully mitigated by optimizing the spraying parameters. Nanohardness values close to 3.6 GPa were observed in both the feedstock powder and coatings, suggesting the absence of cold-working hardening effects during the process. The effects of the substrate surface roughness and thickness on coating quality were investigated. The deposited mass measurements performed on the coatings showed that the effect of using different grit sizes for the substrate preparation is limited to small changes in the deposition efficiency of only the first few layers of deposited material. The SEM observation showed that the substrate surface roughness has no significant effect on the macrostructures and microstructures of the coating. The ability to use the cold gas dynamic spraying process to produce coatings on thin parts without noticeable substrate damage and with the same quality as coatings produced on thicker substrates was demonstrated in this work.

Synthesis and oxidation behavior of nanocrystalline MCrAlY bond coatings

Thermal barrier coating systems protect turbine blades against high-temperature corrosion and oxidation. They consist of a metal bond coat (MCrAlY, M = Ni, Co) and a ceramic top layer (ZrO2/Y2O3). In this work, the oxidation behavior of conventional and nanostructured high-velocity oxyfuel (HVOF) NiCrAlY coatings has been compared. Commercially available NiCrAlY powder was mechanically cryomilled and HVOF sprayed on a nickel alloy foil to form a nanocrystalline coating. Freestanding bodies of conventional and nanostructured HVOF NiCrAlY coatings were oxidized at 1000 °C for different time periods to form the thermally grown oxide layer. The experiments show an improvement in oxidation resistance in the nanostructured coating when compared with that of the conventional one. The observed behavior is a result of the formation of a continuous Al2O3 layer on the surface of the nanostructured HVOF NiCrAlY coating. This layer protects the coating from further oxidation and avoids the formation of mixed oxide protrusions present in the conventional coating.

Cold-Spray processing of a nanocrystalline Al−Cu−Mg−Fe−Ni alloy with Sc

This work describes recent progress in cold-spray processing of conventional and nanocrystalline 2618 (Al−Cu−Mg−Fe−Ni) aluminum alloy containing scandium (Sc). As-atomized and cryomilled 2618+Sc aluminum powder were sprayed onto aluminum substrates. The mechanical behavior of the powders and the coatings were studied using micro-and nanoindentation techniques, and the microstructure was analyzed using scanning and transmission electron microscopy (SEM and TEM). The influence of powder microstructure, morphology, and behavior during deposition on the coating properties was analyzed. This work shows that Al−Cu−Mg−Fe−Ni−Sc coatings with a nanocrystalline grain structure can be successfully produced by the cold-spray process. Inspection of the scientific literature suggests that this is the first time a hardness value of 181 HV has been reported for this specific alloy.

Mechanical Properties of Amorphous Al 85 Ni 10 La 5 Alloy by Indentations

Indentation techniques have been carried out to study the mechanical behavior of amorphous Al 85 Ni 10 La 5 alloy powders produced by inert gas atomization. The present work reveals that this amorphous alloy undergoes a three-stage crystallization process in the temperature range of 250°C ~ 390°C, with a glass transition temperature of approximately 259°C. In this study, the influence of devitrification on mechanical response was investigated via indentation of the Al 85 Ni 10 La 5 alloy powders annealed at various temperatures, for instance, at temperatures well below or close to glass transition (235°C, 245°C, 250°C), and well above glass transition (283°C). Moreover, the microstructure evolution and the formation of nanoscale crystallites were studied using TEM and XRD. The influence of devitrification on the indentation response was characterized, paying particular attention to shear band formation and variations in hardness. The hardening behavior was analyzed on the basis of a rule-of-mixtures approach by treating the partially crystallized alloy as a nanocomposite.