Thermally Enhanced Bonding and Mechanical Properties of Al Deposit for Double-Layered Cu Liner

Al-Ni composite and pure Al coatings were fabricated on copper substrates via kinetic spraying for military applications. The coatings endure the high strain rate severe plastic deformation during explosion. In this study, the mechanical properties and thermal reactivities of the coatings formed under various process conditions were evaluated and compared. The strain accommodation abilities (e.g. elongation-to-failure) and bond strength of the coatings (with and without post-annealing heat treatments) were evaluated via well-designed tensile tests according to the ASTM standards. Based on differential scanning calorimetry (DSC) analysis, the initiation temperature and enthalpy for exothermic reactions of the coatings were also evaluated. These properties of the coatings were discussed in terms of the processing-structure-property relationships.