Journal of Thermal Spray Technology

, Volume 16, Issue 5–6, pp 661–668 | Cite as

Investigation of Al-Al2O3 Cold Spray Coating Formation and Properties

  • Eric Irissou
  • Jean-Gabriel Legoux
  • Bernard Arsenault
  • Christian Moreau
Peer Reviewed

Coating build-up mechanisms and properties of cold-sprayed aluminum-alumina cermets were investigated using two spherical aluminum powders having average diameters of 36 and 81 μm. Those powders were blended with alumina at several concentrations. Coatings were produced using a commercial low-pressure cold spray system. Powders and coatings were characterized by electronic microscopy and microhardness measurements. In-flight particle velocities were monitored for all powders. The deposition efficiency was measured for all experimental conditions. Coating performance and properties were investigated by performing bond strength test, abrasion test, and corrosion tests, namely, salt spray and alternated immersion in saltwater tests. These coating properties were correlated to the alumina fraction either in the starting powder or in the coating.


abrasion resistance corrosion protection gas dynamic spray low-pressure cold spray metal-ceramic mixture 



The authors acknowledge the technical assistance of J.-F. Alarie, F. Belval, B. Harvey, M. Lamontagne and M. Thibodeau.


  1. 1.
    S.H. Thurston, Method of Impacting One Metal Upon Another, U.S. Patent 705,701, August 12, 1902Google Scholar
  2. 2.
    C.F. Rocheville, Device for Treating the Surface of a Workpiece, U.S. Patent 3,100,724, August 13, 1963Google Scholar
  3. 3.
    A.P. Alkhimov, V.F. Kosarev, and A.N. Papyrin, A Method of ‘Cold’ Gas-Dynamic Deposition, Sov. Phys. Doklady, (1990), 35(12), p 1047-1049Google Scholar
  4. 4.
    A. Shkodkin, A. Kashirin, O. Klyuev, and T. Buzdygar, Metal Particle Deposition Stimulation by Surface Abrasive Treatment in Gas Dynamic Spraying, J. Therm. Spray Technol., 2006, 15(3), p 382-386CrossRefGoogle Scholar
  5. 5.
    A.I. Kashirin, O.F. Klyuev, and T.V. Buzdygar, Apparatus for Gas-Dynamic Coating, U.S. Patent 6,402,050, June 11, 2002Google Scholar
  6. 6.
    A.P. Alkhimov, A.N. Papyrin, V.F. Kosarev, N.I. Nesterovich, and M.M. Shushpanov, Gas-Dynamic Spraying Method for Applying a Coating, U.S. Patent 5,302,414, April 12, 1994Google Scholar
  7. 7.
    R.G. Maev and V. Leshchynsky, Air Gas Dynamic Spraying of Powder Mixtures: Theory and Application, J. Therm. Spray Technol., 2006, 15(2), p 198-205CrossRefGoogle Scholar
  8. 8.
    R.G. Maev and V. Leshchinsky, Low Pressure Gas Dynamic Spray: Shear Localization During Particle Shock Consolidation, Building on 100 Years of Success: Proceedings of the 2006 International Thermal Spray Conference, B.R. Marple, M.M. Hyland, Y.C. Lau, R.S. Lima, and J. Voyer, Eds., May 15-18, 2006 (Seattle, WA, USA), ASM International, 2006Google Scholar
  9. 9.
    E. Irissou and B. Arsenault, Corrosion Study of Cold Sprayed Aluminum Coatings onto Al 7075 Alloy Substrates, Global Coating Solutions: Proceedings of the 2007 International Thermal Spray Conference, B.R. Marple, M.H. Hyland, Y.-C. Lau, C.-J. Li, R.S. Lima, and G. Montavon, Eds., May 14-16, 2007, (Beijing, China), ASM International, 2007, p 549-554 Google Scholar
  10. 10.
    Z.B. Zhao, B.A. Gillispie, J.R. Smith, Coating Deposition by the Kinetic Spray Process, Surf. Coat. Technol., 2006, 200(16-17), p 4746-4754CrossRefGoogle Scholar
  11. 11.
    H. Assadi, F. Gartner, T. Stoltenhoff, and H. Kreye, Bonding Mechanism in Cold Gas Spraying, Acta Mater., 2003, 51(15), p 4379-4394CrossRefGoogle Scholar
  12. 12.
    R.C. Dykhuizen and M.F. Smith, Gas Dynamic Principles of Cold Spray, J. Therm. Spray Technol., 1998, 7(2), p 205-212CrossRefGoogle Scholar
  13. 13.
    T. Schmidt, F. Gartner, H. Assadi, and H. Kreye, Development of a Generalized Parameter Window for Cold Spray Deposition, Acta Mater., 2006, 54(3), p 729-742CrossRefGoogle Scholar

Copyright information

© ASM International 2007

Authors and Affiliations

  • Eric Irissou
    • 1
  • Jean-Gabriel Legoux
    • 1
  • Bernard Arsenault
    • 1
  • Christian Moreau
    • 1
  1. 1.National Research Council Canada – Industrial Materials InstituteBouchervilleCanada

Personalised recommendations