Microstructure, Mechanical Properties and Wear Behavior of Cold Gas Sprayed Quasicrystalline (QC) Al-Cu-Fe Coatings

Quasicrystalline (QC) materials are known to provide a unique combination of physical and mechanical properties. These include high hardness, low thermal and electrical conductivity, low friction as well as excellent oxidation and corrosion resistance. In this context, thermal sprayed QC coatings have also received particular attention as they offer great potential for many (future) surface applications. Various thermal spray techniques such as APS and HVOF have been proven to process QC feedstocks and to preserve the aperiodic structure in the coatings. In this study, cold gas spraying of QC Al-Cu-Fe was investigated. The coatings were characterized regarding their mechanical, microstructural and tribological properties. In addition, the particle velocity in flight was determined. XRD analyses with synchrotron radiation as well as an EPMA device were used to evaluate the evolution of the elements and the QC phases in the microstructure.