Effect of process gas and particle size distribution on the deposition of Fe3Al coatings by Cold Gas Spray

Intermetallic compounds made up of two or more elements in a fixed proportion have a different structure than their constituents, which gives them interesting properties. Iron aluminides are well-known for their low cost, high strength-to-weight ratio and excellent oxidation and corrosion resistance at high temperatures. They show excellent properties for their use as a protective coating in hostile atmospheres.

This work aims on the manufacturing of Fe3Al coatings by Cold Gas Spray technology. Different microstructures have been obtained when changing the process gas and particle size distribution. A microstructural evaluation has been carried out in terms of XRD, OM and SEM-EDS. Finally, dense coatings were successfully obtained by Cold Gas Spray, and mechanical properties such as adhesion and hardness have been assessed.