Synthesis of bulk nanostructured aluminum alloy component through vacuum plasma spray technique

The benefits of large-size engineering components with nanocrystalline structure (providing improved strength) are yet to be realized due to processing difficulties and associated grain growth problems. In this work, a free-standing bulk nanocrystalline structure of hyper-eutetic aluminum alloy (Al-21wt.%Si) has been fabricated through the vacuum plasma spray (VPS) forming technique using micron-size powder feedstock. Optical microscopy, scanning electron microscopy and transmission electron microscopy have been used to investigate the evolution of multi-scale microstructure as the result of rapid solidification in VIIS forming process. The characterization implies the presence of nanosized eutectic Al-Si grains (25-100 nm) With uniformly distributed Ultrafine primary silicon particles of submicron size. The effect of microstructural evolution on mechanical properties has been studied by tensile testing and microhardness measurement. A considerable improvement in ultimate tensile strength and hardness of the sprayed deposit has been observed in comparison with conventionally cast hypereutectic Al-17wt.%Si alloys. (c) 2005 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved