Microstructural features associated with spray atomization and deposition of Al-Mn-Cr-Si alloy

An inert gas atomization process was employed in production of rapidly solidified powders as well as disc-shape preform by spray deposition of an Al<SUB>75</SUB>Mn<SUB>10</SUB>Cr<SUB>5</SUB>Si<SUB>10</SUB> alloy. Microstructural features of atomized powders and spray deposited preforms were evaluated by scanning and transmission electron microscopy and X-ray diffractometry techniques. Solidification structure of powders revealed cellular and dendritic morphology, depending on their size. The interdendritic regions consisted of second phase particles. In contrast the spray formed alloy exhibited microstructural homogeneity with distribution of ultra-fine second phase particles of intermetallic compound. The structure of second phase intermetallics was identified as a cubic α -Al(Mn,Cr)Si, in both the atomized powders and the spray-deposits. The formation of cubic phase is discussed as rational approximant structure of an icosahedral quasicrystal