Spray forming of bulk Al85Y8Ni5Co2 with co-existing amorphous, nano- and micro-crystalline structures

A 12 mm thick Al85Y8Ni5Co2 plate was spray deposited on a 30 mm thick pre-heated copper substrate. The deposit was characterized using optical, high resolution scanning and transmission electron microscopy. Differential scanning calorimetry was performed to assess the crystallization behaviour of the deposit compared to melt spun ribbons of the same composition. The deposit shows an amorphous phase fraction of 83 and 56 vol.% (based on the total crystallization energy), in the bottom and top regions of the deposit. The deposit consists of amorphous and nanoscale structures along with microcrystalline intermetallic phases. The large amorphous phase fraction in the deposit is attributed to the chilling effect upon deposition of highly undercooled/partially crystallized droplets onto the pre-heated substrate and rapid heat extraction thereof due to bonding at the deposit/substrate interface.