Effect of reinforcement particles on cold-sprayed Al-based coatings

In this study, malleable and heavy Ta particles were introduced into soft Al powders to prepare Al-Ta composite coatings through a low-pressure cold-spray process; for comparison, Al-A(2)O(3) composite coatings were also deposited. The surface and cross-sectional morphologies, deposition efficiency, microstructure, hardness and composition of the coatings were investigated. The results demonstrated that the Al-Ta coatings had roughness values that were almost twice as large as those of the Al-Al2O3 coatings for the same volumetric fraction of reinforcement particles used in the feedstock. Ta particles were more effective in improving the deposition efficiency and densification than were Al2O3 particles. The formation mechanism of the Al-Ta coatings was mainly attributed to the malleable and heavy nature of Ta particles, which allowed them to bond with the formed coating and impact the coating strongly through the peening effect.