Nanostructured alumina-Ni(Zn) cermet feedstock and cold spray coatings for clean transportation industries

Revolutionary materials design and their atomic scale manufacturing is within the reach with the availability of supersonic/hypersonic technologies in this Industry 4.0 manufacturing era. The focus away from traditional metal/alloy materials based component design and mass manufacturing is a result of enabling technologies supporting the handling of high modulus ceramics and composite materials for ultra-high-strength high-rewarding applications, namely nuclear, aerospace, petrochemical, defence, etc. The goal of this presentation is to showcase the recent ceramic-metallic (cermet) composites design and their additive manufacturing in a high-pressure cold spray process (HPCS). In particular, the design and nanoscale synthesis of particulate feedstock comprising of a hard ceramic oxide nanograin embedded in a Ni(Zn) binder matrix will be divulged, followed by the feedstock deposition and thin coatings development and microstructure evolution in the HPCS method. The pertinent results will connect the mechanical (Young’s modulus, residual stress, nanohardness) properties with the high-impact erosion characteristics of the novel coatings.