Effect of substrate hardness on the deformation behavior of subsequently incident particles in cold spraying

A systematic finite element analysis (FEA) on the subsequently incident particles which refer to the particles depositing after the formation of the first layer coating is conducted in this study to clarify the bonding mechanism inside the cold sprayed coating. A simplified particle impact model is proposed and the simulated results based on this model demonstrate that substrate hardness exerts some effects on the deformation behavior of the subsequently incident particles. Hard substrate makes these particles deform intensively but using soft substrate enables them to achieve a slight deformation. At the same time, it is also found that substrate hardness plays its best role only when the formed coating is thin, as the development of the coating, the particle deformation behavior becomes more and more insensitive to the substrate hardness. The multi-particle impact simulation based on Eulerian method is also performed and reaches the same conclusion, confirming the accuracy of the simplified model. Besides, it is also found that when the velocity is increased to a hypervelocity, excessive deformation occurs in the formed coatings due to the impact of the subsequently incident particles.     

Quantitative TEM analysis of Al/Cu multilayer systems prepared by pulsed laser deposition

Thin films composed of alternating Al/Cu/Al layers were deposited on a (111) Si substrate using pulsed laser deposition (PLD). The thicknesses of the film and the individual layers, and the detailed internal structure within the layers were characterized by means of transmission electron microscopy (TEM), high-resolution TEM (HRTEM), and energy-filtered TEM (EFTEM). Each Al or Cu layer consists of a single layer of nano-sized grains of different orientations. EFTEM results revealed a layer of oxide about 2 nm thick on the surface of the Si substrate, which is considered to be the reason for the formation of the first layer of nano-sized Al grains. The results demonstrate that the PLD technique is a powerful tool to produce nano-scale multilayered metal films with controllable thickness and grain sizes.     

Interaction between localized and propagating surface plasmons: Ag fine particles on Al surface

Samples consisting of Ag fine particles 4nm in size placed near to an Al surface were prepared by depositing Ag-SiO₂ composite films by a rf cosputtering method onto vacuum-evaporated Al films. Angle-scan attenuated total reflection (ATR) measurements were performed over a wide wavelength range (λ=350-630nm) covering the resonance region (λ-410nm) of localized surface plasmon (LSP) in the Ag particles. It was found that the existence of Ag fine particles near to the Al surface led to a deformation of the dispersion curve of the surface plasmon polariton (SPP) propagating on the Al surface, in particular, in the LSP resonance region. The interaction between LSP and SPP was found to become much stronger as the distance between the particles and the surface decreases. The theoretical calculations based on the effective medium theory, which gave an effective dielectric function of the Ag-SiO₂ composite film, reproduced the deformation of the dispersion curve of the SPP. The deformation of the dispersion observed experimentally was qualitatively explained by the behavior of the effective dielectric function of the Ag-SiO₂ composite film.     

Significant influences of metal reactivity and oxide films at particle surfaces on coating microstructure in cold spraying

Based on large amount of experimental observations, the effects of metal reactivity and oxide films at particle surfaces on coating deposition behavior in cold spraying were presented and discussed. The oxygen contents in as-sprayed Ti, Ti-6Al-4V and Al coatings were higher than those in the corresponding starting powders. The obvious flashing jets outside nozzle exit during deposition of Ti and Ti-6Al-4V were caused by the reaction of the particles with oxygen in the entrained or the adopted air. For Ti and Ti-6Al-4V coatings, their porous structures are predominantly attributed to the surface reactivity (defined as reactivity with oxygen). This surface reaction could be helpful for formation of a metallurgical bonding between the deposited particles. For Al, even though it is more reactive than Ti, the oxide films at Al particle surfaces suppress the surface activity.     

Atomistic study of deposition process of Al thin film on Cu substrate

In this paper we report molecular dynamics based atomistic simulations of deposition process of Al atoms onto Cu substrate and following nanoindentation process on that nanostructured material. Effects of incident energy on the morphology of deposited thin film and mechanical property of this nanostructured material are emphasized. The results reveal that the morphology of growing film is layer-by-layer-like at incident energy of 0.1-10 eV. The epitaxy mode of film growth is observed at incident energy below 1 eV, but film-mixing mode commences when incident energy increase to 10 eV accompanying with increased disorder of film structure, which improves quality of deposited thin film. Following indentation studies indicate deposited thin films pose lower stiffness than single crystal Al due to considerable amount of defects existed in them, but Cu substrate is strengthened by the interface generated from lattice mismatch between deposited Al thin film and Cu substrate.     

Plasma splashing from Al and Cu materials induced by an Nd:YAG pulsed laser

Plasma splashing from Al and Cu target materials and the growth of thin films on Cu and Al, respectively, has been studied using a Q-switched Nd:YAG laser with a 1064-nm, 80-mJ, 8-ns pulse width as the source of ablation. The target kept rotating and the substrate, Cu for Al and vice versa, was placed at an angle of 15° with respect to the beam axis. During the laser-matter interaction, the targets absorbed thermal energy within the thermal region depth of 4.7 (1.1) nm, yielding an ablated skin depth of 6.7 (4.2) nm. The surface morphology of the exposed targets was studied by analyzing SEM micrographs obtained using a ZEISS SUPRA 35 VP. The obtained results are explained on the basis of different sputtering/ablation mechanisms. Comparatively severe damage forming a bigger crater is seen on the Al target surface in contrast to the crater on the Cu surface. This observation is correlated with the blustering effect and/or debris formation. Energy dispersive spectroscopy (EDX) of the substrates yielded the deposition of micrometric grain-size particles.     

溅射Al对AlN的“润湿”与钎焊

由于润湿性不佳, 难以实现金属钎料对陶瓷的无过渡层直接钎焊, 本文在研究了溅射Al薄膜对AlN的“润湿”作用的基础上, 通过磁控溅射的方法在AlN表面沉积Al基薄膜作为钎料, 在真空条件下对AlN陶瓷进行了直接钎焊. 采用高景深光学显微镜、扫描电子显微镜和X射线能量分散谱表征了钎焊接头和剪切断口的组织及形貌. 结果表明, 高能量溅射Al粒子对AlN的撞击可以形成只有850 ℃以上高温才可获得的Al-N化学键, 实现Al对AlN的“润湿”, 使Al基薄膜钎料能够在较低的温度(≥ 510 ℃)对AlN直接钎焊. 此方法获得的Al/AlN接头的剪切强度达到104 MPa, 含3.8 at.% Cu的Al合金钎料接头强度可进一步提高到165 MPa, 它们的剪切断裂都产生于钎缝金属之中; 增加钎料中的Cu含量至9.1 at.%后, Cu在钎缝与陶瓷界面的偏聚使接头的剪切强度降低为95 MPa. Al-20 at.% Ge合金可以将钎焊温度降低至510 ℃, 但Ge在钎缝与陶瓷界面的偏聚使接头在48 MPa发生断裂.     

原位自生20vol.％TiCP/LD7Al基复合材料蠕变的应力指数和门槛应力

在523 K,573 K和623 K恒应力压缩条件下研究了原位自生20vol%TiC_p/LD7Al基复合材料和LD7Al合金的高温蠕变行为.对蠕变速率与外加应力在双对数坐标中进行拟合,获得了复合材料和基体铝合金的应力指数;通过在幂率方程中引入有效应力（σ-σ₀）,对实验数据进行线性回归外推至零蠕变速率得到相应的门槛应力.实验结果显示,复合材料的应力指数和门槛应力均高于LD7Al合金.TiC颗粒的存在,明显改善了LD7Al合金的高温蠕变 关键词： p/LD7Al基复合材料')" href="#">TiC_p/LD7Al基复合材料 蠕变 应力指数 门槛应力     

PTFE/Al反应材料的力学性能研究

 反应材料是一种由冲击引发的新型含能材料,对其力学性能的研究是其广泛应用的一个重要前提。在室温下,利用万能试验机和改进的摆锤冲击试验机对聚四氟乙烯/铝（PTFE/Al）系列反应材料的拉伸和冲击性能进行了实验研究。随着Al含量的增加,反应材料的密度和燃烧热升高,拉伸强度呈先升高后降低的趋势,在Al含量为6%左右时达到最大值36.1 MPa,与计算结果较符合。推测反应材料的损伤过程为变形、开裂和反应3步。Al含量的增加导致反应材料试样的冲击韧性先升高后降低,在Al含量为40%左右时达到最大值72.06 J/cm²。随着Al含量的增加,材料的反应难度增加,反应自持性降低。     

Al/ZnO/Al薄膜的结构与磁性分析

采用直流磁控溅射的方法制备了Al/ZnO/Al纳米薄膜,并对薄膜分别在真空及空气中进行退火处理.利用X射线衍射仪(XRD)和物理性能测量仪(PPMS)分别对薄膜样品的结构和磁性进行了表征.XRD分析表明,不同的退火氛围对薄膜的微结构有着很大的影响.采用了一种新的修正方法对磁测量结果进行修正,计算了基底拟合误差的最大值,并对修正后样品的磁性进行了分析.结果显示,室温铁磁性可能与Al和ZnO基体之间发生的电荷转移以及在不同退火氛围下Al在ZnO晶格中的地位变化有关. 关键词： Al/ZnO/Al薄膜 铁磁性 磁性表征     

Numerical investigations of the effect of oblique impact on particle deformation in cold spraying by the SPH method

In this study, a systematic examination of the oblique impacting of copper particles in cold spraying was conducted by using the smoothed particle hydrodynamics (SPH) method compared to the Lagrangian method. 3D models were employed owing to the asymmetric characteristic of the oblique impacting. It is found that in the oblique impact, the additional tangential component of particle velocity along the substrate surface could create a tensile force and decrease the total contact area and bonding strength between the particle and the substrate. The simulation results compare fairly well to the experiment results. Meanwhile, the asymmetric deformation can result in the focus of the shear friction on a small contact zone at one side, which may rise the interfacial temperature and thus facilitate the occurrence of the possible shear instability. Therefore, there probably exists an angle range, where the deposition efficiency may be promoted rather than the normal angle. Moreover, the particle deformation behavior simulated by the SPH method is well comparable to that simulated by the Lagrangian method and the experimental results, which indicates the applicability of the SPH method for simulating the impact process in cold spraying besides the previously used Arbitrary Lagrangian Eulerian (ALE) method.     

Effect of Al doping on microstructure and optical band gap of ZnO thin film synthesized by successive ion layer adsorption and reaction

Thin films of pure and aluminum-doped zinc oxide (AZO) were deposited on glass substrates from ammonium zincate bath following a chemical dipping technique called successive ion layer adsorption and reaction (SILAR). Characterization techniques such as X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy-dispersive X-rays (EDX) were used to investigate the effect of Al doping on the microstructure of AZO films. Particle size analysis using X-ray line broadening shows marginally increasing trend with increasing Al impurity. The average particle size for pure ZnO is 22.75 nm. It increases to 24.26 nm for 1% AZO film and 25.13 nm for 2% AZO film. Incorporation of Al was confirmed from elemental analysis using EDX. SEM micrograph shows that pure ZnO particles are spherical shaped. However, AZO films show particles with off-spherical shape with compact interconnected grains. The value of band gap for pure ZnO is 3.229 eV and it increases to 3.29 eV for 1% AZO indicating a blue-shift for 1% AZO film. However, for 2% AZO film, a decrease in band gap compared to pure ZnO is observed indicating a red-shift of fundamental absorption edge. Electrical resistance shows an initial decrease with increasing Al content. With further enhancement of Al incorporation, the resistance increases.     

Nanoporous Al sandwich foils using size effect of Al layer thickness during Cu/Al/Cu laminate rolling

The roll bonding technique is one of the most widely used methods to produce metal laminate sheets. Such sheets offer interesting research opportunities for both scientists and engineers. In this paper, we report on an experimental investigation of the ‘thickness effect’ during laminate rolling for the first time. Using a four-high multifunction rolling mill, Cu/Al/Cu laminate sheets were fabricated with a range of thicknesses (16, 40, 70 and 130 μm) of the Al layer. The thickness of the Cu sheets was a constant 300 μm. After rolling, TEM images show good bonding quality between the Cu and Al layers. However, there are many nanoscale pores in the Al layer. The fraction of nanoscale pores in the Al layer increases with a reduction in the Al layer thickness. The finite element method was used to simulate the Cu/Al/Cu rolling process. The simulation results reveal the effect of the Al layer thickness on the deformation characteristics of the Cu/Al/Cu laminate. Finally, we propose that the size effect of the Al layer thickness during Cu/Al/Cu laminate rolling may offer a method to fabricate ‘nanoporous’ Al sandwich laminate foils. Such foils can be used in electromagnetic shielding of electrical devices and noisy shielding of building.     

Significant influence of particle surface oxidation on deposition efficiency, interface microstructure and adhesive strength of cold-sprayed copper coatings

The critical velocity for particle deposition in cold spraying is a key parameter, which depends not only on the material type, but also the particle temperature and oxidation condition. The dependency of deposition efficiency of cold spray Cu particles on the particle temperature and surface oxidation was examined. The effect of particle surface oxide scales on the interfacial microstructure and adhesive strength of the cold-sprayed Cu coatings was investigated. The results show that the deposition efficiency significantly increases with increasing the gas temperature but decreases with augmenting the oxygen content of the starting powder. The oxide inclusions at the interfaces between the deposited particles inhibit the effective bonding of fresh metals and remarkably lower the bond strength of the deposited Cu coatings on steel.     

Influence of Al3Ni crystallisation origin particles on hot deformation behaviour of aluminium based alloys

Abstract

Binary Al–Ni, Al–Mg and ternary Al–Mg–Ni alloys containing various dispersions and volume fraction of second-phase particles of crystallisation origin were compressed in a temperature range of 200–500 °C and at strain rates of 0.1, 1, 10, 30 s^?1 using the Gleeble 3800 thermomechanical simulator. Verification of axisymmetric compression tests was made by finite-element modelling. Constitutive models of hot deformation were constructed and effective activation energy of hot deformation was determined. It was found that the flow stress is lowered by decreasing the Al₃Ni particle size in case of a low 0.03 volume fraction of particles in binary Al–Ni alloys. Intensive softening at large strains was achieved in the alloy with a 0.1 volume fraction of fine Al₃Ni particles. Microstructure investigations confirmed that softening is a result of the dynamic restoration processes which were accelerated by fine particles. In contrast, the size of the particles had no influence on the flow stress of ternary Al–Mg–Ni alloy due to significant work hardening of the aluminium solid solution. Atoms of Mg in the aluminium solid solution significantly affect the deformation process and lead to the growth of the effective activation energy from 130–150 kJ/mol in the binary Al–Ni alloys to 170–190 kJ/mol in the ternary Al–Mg–Ni alloy.     

(Cu,Al)掺杂ZnO薄膜表面处缺陷的拉曼光谱研究

采用电感耦合等离子体增强物理气相沉积法制备了(Cu,Al)掺杂ZnO薄膜,超导量子干涉磁强计测试结果表明,薄膜具有室温的铁磁性。采用激光共聚焦拉曼(Raman)光谱研究了(Cu,Al)掺杂ZnO薄膜的表面特性,以两种处理方式对薄膜进行了Raman光谱测试:共聚焦模式从薄膜表面开始至不同深度处进行测试;对薄膜样品进行预处理加工,采用面扫描模式在薄膜平面对(Cu,Al)掺杂ZnO薄膜的斜面进行测试。分析了Raman光谱A₁(LO)峰的中心位置和强度变化,结果表明,界面处晶格应力和缺陷明显增强。这些晶格畸变和点缺陷的存在会对体系的铁磁性有促进作用。     

基底温度对中阶梯光栅厚铝膜质量的影响

大尺寸中阶梯光栅具有大孔径和极高的衍射级次,可以实现普通光栅难以达到的极高光谱分辨率。中阶梯光栅通常是利用刻划机在厚铝膜上刻划而成,所以制备大面积均匀性的高质量铝膜刻划基底是实现高性能大尺寸中阶梯光栅的关键因素。在较厚铝膜的制备工艺中,基底温度是至关重要的工艺参数。本文通过电子束热蒸发镀铝工艺在不同基底温度下制备了厚铝膜样品,并利用原子力显微镜、扫描电镜等手段从宏观和微观尺度详细分析了基底温度对铝膜质量的影响。铝膜平均晶粒尺寸从100℃时的264.34 nm增大到200℃时的384.97 nm和300℃时的596.35 nm,表面粗糙度Rq从100℃时的34.7 nm增长到200℃时的58.9 nm和300℃时的95.1 nm。结果表明,随着基底温度的升高表面粗糙度迅速增大,铝膜的表面质量严重退化。     

Fe/Al混合膜的PLD法制备及表面分析

 采用脉冲激光气相沉积（PLD）技术制备了Fe/Al混合膜,测量了该混合膜的光电子能谱（XPS）,并采用原子力显微镜（AFM）、扫描电子显微镜（SEM）对Fe/Al混合膜作了表面分析。结果表明：Fe/Al混合膜的表面粗糙度对衬底温度有明显的依赖性, 随着衬底温度的升高,薄膜的表面逐渐变得平滑,膜层变得致密,在200 ℃衬底温度下制得了均方根（rms）粗糙度为0.154 nm、具有原子尺度光滑性的Fe/Al混合膜, 膜中Fe和Al分布比较均匀,其成分比约为1∶3,同时XPS分析也表明Fe/Al混合膜暴露在空气中后表面形成了Al₂O₃和FeO氧化层。     

Surface segregation of Al substrate metal on Zr film surface

Segregation of substrate Al on thin Zr film, Zr/Al/Al system was investigated by heating the specimen in a UHV chamber. Dual-cathode magnetron-sputtering source was used for deposition of Zr film as well as thin Al film to avoid aluminum oxide formation at Zr/Al interface. Al segregates on Zr film surface at 730 K. It was found that oxide-free interface between film and substrate is important for segregation in Al system. The diffusion coefficient calculated for surface segregation and inter-metallic compound showed that the grain boundary diffusion and bulk diffusion are very close in Zr/Al/Al system. Hence, it is important to control specimen heating to cause surface segregation by grain boundary diffusion.