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Investigation on the microstructure, phase formation and properties of aluminium alloy coatings by stud spraying

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Abstract

This study aims to investigate a novel spraying technology. The spraying technology is named stud spraying since it has been developed by improving the traditional stud-welding process. Al–Cu coatings have been prepared on the surface of copper plates by using aluminium studs with bosses, and the thickness of the coating centre can be 15–30 μm under the height of stud boss (0.2 mm). The microstructure, phase structure and composition of the coating are characterized. The results show that a large number of Al–Cu intermetallic compounds and a few oxides are present in the coating. Numerous growth crystals are present at the metal interface between the coatings and the copper plate. The crystal morphology of the interface metal is growing from the copper plate to the coating metal which has also been enhanced the coating interface. The stud-coating process is a rapidly cooling solidification process that a variety of intermetallic compounds including θ phase (Al2Cu), η2 phase (Al48Cu52), ζ2 phase (Al9Cu11) and γ2 phase (Al4Cu9) are present within the layers. In addition, multiphase intermetallic compounds enhanced the surface microhardness of the coating with its value increasing from 85 to 222 HV.

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The authors declare that data supporting the findings of this study are available within the article.

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Acknowledgements

This work is supported by the Natural Science Foundation of Gansu Province, China (No. 20JR5RA416, 21JR7RA308), the National Natural Science Foundation of China (No. 51605384), the Foundation of the Young Teachers in Lanzhou Jiaotong University (2017049) and the “Innovation Star” Project for outstanding graduate students in Gansu Province (No. 2022CXZX-537).

Funding

This study was funded by Innovation Star Graduate Research and Innovation Projects of Gansu Province, No. 2022CXZX-537, Xinhong Lu, Natural Science Foundation of Gansu Province, 20JR5RA416, Xilong Zhao, 21JR7RA308, Xilong Zhao, Youth Science Foundation of Lanzhou Jiaotong University, 2017049, Kun Wang.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Lanzhou Jiaotong University, Anning west road, No 88, Lanzhou, 730070, People’s Republic of China

    Xilong Zhao, Xinhong Lu & Feng He

  2. School of Civil Engineering, Lanzhou Jiaotong University, Lanzhou, China

    Kun Wang

Authors
  1. Xilong Zhao
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  2. Xinhong Lu
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  3. Kun Wang
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  4. Feng He
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Contributions

ZX: Conceptualization, original draft, supervision, funding acquisition, review and editing; LX: Experiment, investigation; WK: Picture production; HF: Data processing, Data validation.

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Correspondence to Xilong Zhao.

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Zhao, X., Lu, X., Wang, K. et al. Investigation on the microstructure, phase formation and properties of aluminium alloy coatings by stud spraying. J Mater Sci: Mater Electron 33, 22256–22269 (2022). https://doi.org/10.1007/s10854-022-09004-z

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  • DOI: https://doi.org/10.1007/s10854-022-09004-z

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