Novel microstructural characteristics and properties of spray formed Al-RE-TM based alloys

Abstract

Recent studies on the synthesis of bulk Al-RE (Rare Earth)-TM (Transition Metal) based alloys, from melt spun ribbons and gas atomized powders, have shown that a partially amorphous or nano-crystalline structures lead to a high specific strength. In the present study, therefore, spray atomization and deposition process has been used to produce plates of Al85Y8Ni5Co2 (deposit D1) and Al83Y5La5Ni5Co2 (deposit D2) based alloys so as to synthesize bulk deposit of nano-crystalline and/or partial amorphous matrix composite in a single step. The rapid solidification and high undercooling of droplets during atomization and a chilling effect on undercooled liquid upon deposition are expected to give rise to the above microstructural features. The microstructural features of deposits as well as overspray powders were studied using optical, scanning and transmission electron microscope. The alloys invariably showed a large fraction of nano-crystalline and amorphous structures, characterized by featureless regions at optical resolution, along with distribution of primary equilibrium phases. The differential scanning calorimetric (DSC) analysis of the deposits showed all the crystallization peaks as is observed during crystallization of fully amorphous melt spun ribbons of respective compositions. A glass transition phenomenon is observed in Al-Y-Ni-Co based deposit. The transmission electron microscopy of deposit D1 showed the presence of 50-100 nm size fcc-Al precipitates in an amorphous matrix decorated with 5-20 nm fcc-Al crystallites. The annealing treatment of deposits at different temperatures, determined from the crystallization peaks of the deposit, showed precipitation of nanoscale fcc-Al and intermetallic phases giving rise to a remarkable increase in hardness. The bulk hardness of the deposits D1 and D2 was 391 and 427 HV, respectively. Whereas, the heat treated deposits showed a bulk hardness value of 476 HV for deposit D1 at 298 oC and 582 HV for deposit D2 at 380 oC. An attempt has been made to bring out the possible mechanism of microstructural evolution during spray deposition of these alloys, and the effect of microstructural features on the mechanical properties has been discussed.