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MAX phase ceramic coatings fabricated by aerosol cold spray
* 1, 2 , 1 , 3 , 1
1  Łukasiewicz Research Network – Poznań Institute of Technology, 6 Ewarysta Estkowskiego St., Poznan 61-755, Poland
2  Faculty of Materials Engineering and Technical Physics, Poznan University of Technology, 24 Jana Pawla II St., Poznan 61-138, Poland
3  Institute of Materials Science and Engineering, Poznan University of Technology, 24 Jana Pawla II St., Poznan 61-138, Poland
Academic Editor: Luca Magagnin

Abstract:

MAX phases are a promising material group for high-temperature coating applications. Currently, the search for sustainable MAX phase synthesis and coating techniques suitable for this particular material group is still ongoing. One of the most promising method is cold spray, which prevents the thermally-induced phase changes of the coating material during deposition, while drastically reducing the energy and gas required for the process in comparison to other thermal spraying techniques. In this work, a modified low pressure cold spray (LPCS) system – aerosol cold spray (ACS) has been successfully used to fabricate Ti2AlC, Cr2AlC and Ti3AlC2 coatings on carbon steel substrate. Structural and microstructural analysis indicated successful deposition of dense and crack-free coating without inducing phase changes during the spraying process using compressed air as process gas. Additionally, post-processing of the coatings by free- and spark plasma sintering methods were tested. The analysis of post-processed coating’s microstructure indicated the increase of interparticle bonding within the coating, however free sintering method resulted in cracking within Ti3AlC2 coating, and formation of porosity in Cr2AlC coating, due to intense diffusion of aluminum towards the carbon steel substrate. This work presents the first successful deposition of MAX phase coatings using a LPCS-based technique, as well as post-processing and characterization of their structural and mechanical properties.

Keywords: aerosol cold spray; max phase; spark plasma sintering; free sintering

 
 
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