Nanostructured Al-Based Metal Matrix Composite Coating Production by Pulsed Gas Dynamic Spraying Process

The advantage of combining cryomilling and pulsed gas dynamic spraying (PGDS) processes in order to produce a nanostructured, dense and wear resistant coating was demonstrated. Cryomilling was successfully employed to synthesize particulate B4C reinforced Al matrix nanocomposite feedstock powders, while the PGDS process shows the ability of preserving the microstructure of the starting material. In this study, nanocrystalline and conventional Al5356 + 20%B4C composite as well as the unreinforced Al5356 alloy feedstock powders were used. The influence of the nature of the feedstock material on the microstructure and mechanical properties of the coatings was studied. The PGDS process provides an opportunity to preserve the phase of the starting material, to produce hard and dense coatings with good cohesion between deformed particles and good adhesion to the substrate. High dry sliding wear resistance was observed when cryomilled composite material was used.