Abstract
This study deals with two new material deposition processes in which raw materials are in the form of a thixotropic slurry. In one case, the slurry (Al2O3 nanoparticles in an acrylic resin) is misted into an arc plasma jet and sprayed on a stainless steel substrate. By varying the volume content of nanoparticles and slurry supply rates, investigators were able to achieve uniform droplets, resulting in fine Al2O3 layers free of microcracks and pores. In the other process evaluated, pure aluminum particles were dispersed in a photosensitive resin, producing a slurry that was spread on stainless steel substrates then patterned with a UV laser. The patterned metal particles were heat treated, creating iron-aluminide intermetallic phases through reaction diffusions. The microstructure and composition of the patterned lines are analyzed by SEM and XRD and surface stress distributions associated with a Hilbert fractal pattern are simulated via finite element analysis.
