Plasma Sprayed NiAl Intermetallic Coating Produced with Mechanically Alloyed Powder

Abstract Ni-Al intermetallics have excellent corrosion and oxidation resistance, but their use in thermal spraying has been limited due to issues with in-flight oxidation. In this study, a novel approach is proposed to remove oxide from Ni-Al droplets in-flight by adding a deoxidizer (diamond) to the feedstock powder. A mixture of nickel, aluminum, and diamond powders was mechanically alloyed using a combination of cryogenic and planetary ball milling. The resulting Ni/Al/diamond composite powder was then plasma sprayed via the APS process, forming Ni-Al coatings on Inconel 738 substrates. Phase composition, microstructure, porosity, and microhardness of the coatings were characterized by X-ray diffraction, scanning electron microscopy, image analysis, and hardness testing, respectively. Oxygen content measurements showed that the coatings contained significantly less oxygen than coatings made from ordinary Ni/Al powders. In-flight particle temperatures were also measured and found to be higher than 2300 °C. The low oxygen content in the coatings is attributed to the in-situ deoxidizing effect of ultrahigh temperature droplets which are also oxide-free.

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Microstructure of mechanically alloyed and hot-pressed Al5CuZr2

Proceedings, annual meeting, Electron Microscopy Society of America ◽

10.1017/s0424820100177982 ◽

1990 ◽

Vol 48 (4) ◽

pp. 970-971

Author(s):

T. E. Mitchell ◽

P. B. Desch ◽

R. B. Schwarz

Keyword(s):

Mechanical Alloying ◽

Vickers Hardness ◽

Hot Pressing ◽

Rapid Quenching ◽

Hardened Steel ◽

Alloyed Powder ◽

Ion Milling ◽

Mechanical Grinding ◽

Mechanically Alloyed ◽

Steel Container

Al3Zr has the highest melting temperature (1580°C) among the tri-aluminide intermetal1ics. When prepared by casting, Al3Zr forms in the tetragonal DO23 structure but by rapid quenching or by mechanical alloying (MA) it can also be prepared in the metastable cubic L12 structure. The L12 structure can be stabilized to at least 1300°C by the addition of copper and other elements. We report a TEM study of the microstructure of bulk Al5CuZr2 prepared by hot pressing mechanically alloyed powder.MA was performed in a Spex 800 mixer using a hardened steel container and balls and adding hexane as a surfactant. Between 1.4 and 2.4 wt.% of the hexane decomposed during MA and was incorporated into the alloy. The mechanically alloyed powders were degassed in vacuum at 900°C. They were compacted in a ram press at 900°C into fully dense samples having Vickers hardness of 1025. TEM specimens were prepared by mechanical grinding followed by ion milling at 120 K. TEM was performed on a Philips CM30 at 300kV.

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Effect of Small Iron, Chromium and Boron Additions as Alloying Elements on Microstructure and Mechanical Properties of Ni3Al

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.23.123 ◽

2007 ◽

Vol 23 ◽

pp. 123-126

Author(s):

Radu L. Orban ◽

Mariana Lucaci

Keyword(s):

Mechanical Properties ◽

Tensile Strength ◽

Room Temperature ◽

Alloying Elements ◽

Alloyed Powder ◽

Mechanically Alloyed ◽

Powder Mixtures ◽

B Additions ◽

Strength And Ductility ◽

Iron Chromium

This paper investigates the effect of Fe, Cr and B additions, in small proportions, as alloying elements in Ni3Al with the purpose to reduce its intrinsic fragility and extrinsic embrittlement and to enhance, in the same time, its mechanical properties. It represents a development of some previous research works of the authors, proving that Ni3Al-Fe-Cr-B alloys obtained by reactive synthesis (SHS) starting from Mechanically Alloyed powder mixtures have superior both room temperature tensile strength and ductility, and compression ones at temperatures up to 800 °C, than pure Ni3Al. These create premises for their using as superalloys substitutes.

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