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Scratch-Induced Deformation Behavior of Cold-Sprayed Aluminum Amorphous/Nanocrystalline Coatings at Multiple Load Scales

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Abstract

Scratch-induced deformation behavior of cold-sprayed Al amorphous/nanocrystalline alloy coatings at multiple load scales is reported. Micro-scratch tests are carried out at several loads (1000-4000 μN) in constant and ramp loading conditions. Macro/high load scratch tests are carried out at 5 N load in ramp loading conditions. The deformation of as-sprayed and heat-treated coatings is analyzed in terms of scratch morphology, and friction. A lower coefficient of friction (COF) is obtained for as-sprayed coatings. Despite lower COF, as-sprayed coatings show a higher wear volume loss (4 times in micro-scratch and 1.4 times in macro-scratch) as compared to heat-treated coatings. Fluctuations were observed in COF along the scratch length of as-sprayed coatings in micro-scratch tests, which are correlated to the shear band formation. Higher scratch wear resistance is observed in the heat-treated coatings as compared to as-sprayed coatings due to denser microstructure with embedded intermetallic phases. Scratch-induced deformation behavior changed from the shear band dominated brittle mode in as-sprayed to plowing type in the heat-treated coatings.

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Acknowledgments

Suresh Babu acknowledges the financial support from Indo-US Science and Technology Forum (IUSSTF) India under Indo-US Fellowship program and Florida International University for permitting to use Advanced Materials Engineering Research Institute (AMERI) facilities. Suresh Babu thanks ARCI management for kind permission to work at FIU, Miami. AA thanks Dr. S. Scudino (IFW, Dresden, Germany) for providing the powder feedstock and Dr. J. Karthikeyan (ASB Industries, OH, USA) for assisting with cold spraying.

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Authors and Affiliations

  1. International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), Balapur, Hyderabad, 500 005, Andhra Pradesh, India

    Suresh Babu Pitchuka & G. Sundararajan

  2. Nanomechanics and Nanotribology Laboratory, Department of Mechanical and Materials Engineering, Florida International University, Miami, FL, 33174, USA

    Suresh Babu Pitchuka, Debrupa Lahiri & Arvind Agarwal

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  1. Suresh Babu Pitchuka
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  2. Debrupa Lahiri
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Correspondence to Arvind Agarwal.

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Pitchuka, S.B., Lahiri, D., Sundararajan, G. et al. Scratch-Induced Deformation Behavior of Cold-Sprayed Aluminum Amorphous/Nanocrystalline Coatings at Multiple Load Scales. J Therm Spray Tech 23, 502–513 (2014). https://doi.org/10.1007/s11666-013-0021-x

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