The Cold Spray coatings have been sprayed from binary eutectic alloy – Al-12%Si and from the complex composition iron-based alloy. The atomized Al-Si powder had close to microcrystalline (grain size around 1micron) structure, the Fe alloy powder had amorphous-nanocrystalline structure. Aluminum-based alloy was also sprayed with addition of up to 10% of aluminum oxide powder. The coating structure and properties have been investigated using optical microscopy, scanning electron microscopy, energy dispersive spectrometry, X-ray diffraction, microcalorimetry, microhadness, tensile, bend, erosion and abrasion tests, and corrosion polarization tests. It has been shown that the Al-Si coatings have microcrystalline structure, and the Fe-based coating have amorphous-nanocrystalline structure similar but not identical to the feedstock powders. Cold Spray process has a specific mechanism to preserve the powders metastable structures. The coatings have enhanced hardness, wear and corrosion resistance. Abstract only; no full-text paper available.

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