CuAl2 intermetallic powders were consolidated using an atmospheric plasma spraying process. Based on X-ray diffractometry results, no phase change occurred during thermal spraying. The investigation of optical micrographs showed that about 7% porosity was present in the microstructure of the coatings. The coatings showed hardness value up to 575 HV(50 g). The polarisation tests and electrochemical spectroscopy measurements were utilised for electrochemical investigation of the coatings in 1 M H2SO4 and 3.5% NaCl media. In H2SO4 environment, the coated and uncoated samples showed similar corrosion rates. However, the coating showed a lower corrosion rate than the substrate in NaCl solution by an order of magnitude. Corrosion of the steel substrate occurred in the NaCl solution, no corrosion was observed in the H2SO4.
XuH., LiuC., SilberschmidtV. V., PramanaS. S., WhiteT. J., ChenZ. and AcoffV. L.: ‘Behavior of aluminum oxide, intermetallics and voids in Cu–Al wire bonds’, Acta. Mater., 2011,
59, 5661–5673. doi: 10.1016/j.actamat.2011.05.041
2.
KoutersM. H. M., GubbelsG. H. M. and FerreiraO. D. S.: ‘Characterization of intermetallic compounds in Cu–Al ball bonds: Mechanical properties, interface delamination and thermal conductivity’, Microelectron. Reliab., 2013,
53, 1068–1075. doi: 10.1016/j.microrel.2013.02.020
3.
de la RosaF., Romero-RomeroJ. R., López-MirandaJ. L., Hernández-TorresA. G. and RosasG.: ‘Phase transformation of the CuAl2 intermetallic alloy during high-energy ball-milling’, Intermetallics, 2015,
61, 51–55. doi: 10.1016/j.intermet.2015.02.015
4.
LimA. B. Y., LongX., ShenL., ChenX., RamanujanR. V., GanC. L. and ChenZ.: ‘Effect of palladium on the mechanical properties of Cu–Al intermetallic compounds’, J. Alloys Compd., 2015,
628, 107–112. doi: 10.1016/j.jallcom.2014.12.119
5.
OsórioW. R., SpinelliJ. E., FreireC. M. A., CardonaM. B. and GarciaA.: ‘The roles of Al2Cu and of dendritic refinement on surface corrosion resistance of hypoeutectic Al–Cu alloys immersed in H2SO4’, J. Alloys Compd., 2007,
443, 87–93. doi: 10.1016/j.jallcom.2006.10.010
6.
GrinY., WagnerF. R., ArmbrüsterM., KohoutM., Leithe-JasperaA., SchwarzU., WedigU. and SchneringH. G.: ‘CuAl2 revisited: Composition, crystal structure, chemical bonding, compressibility and Raman spectroscopy’, J. Solid State Chem., 2006,
179, 1707–1719. doi: 10.1016/j.jssc.2006.03.006
7.
DuguetT., KenzariS., DemangeV., BelmonteT., DuboisJ. M. and FournéeV.: ‘Structurally complex metallic coatings in the Al–Cu system and their orientation relationships with an icosahedral quasicrystal’, J. Mater. Res., 2010,
25, 764–772. doi: 10.1557/JMR.2010.0101
8.
MacchioniC., RayneJ. A., SenS. and BauerL.: ‘Low temperature resistivity of thin film and bulk samples of CuAl2 and Cu9Al4’, Thin Solid Film, 1981,
81, 71–78. doi: 10.1016/0040-6090(81)90506-X
9.
HaidaraF., RecordM. C., DuployerB. and MangelinckD.: ‘Investigation of reactive phase formation in the Al–Cu thin film systems’, Surf. Coat. Technol., 2012,
206, 3851–3856. doi: 10.1016/j.surfcoat.2012.01.065
10.
MannaI. and MajumdarJ. D.: ‘Enhanced kinetics of diffusion coating of aluminium on copper by boundary diffusion’, J. Mater. Sci. Lett., 1993,
12, 920–922. doi: 10.1007/BF00455619
DavisJ. R.: ‘Handbook of thermal spray technology’, 2008, Materials Park, OH
, ASM International.
13.
PaksereshtA., RahimipourM., VaeziM. and SalehiM.: ‘Effect of morphology and nonbounded interface on dielectric properties of plasma sprayed BaTiO3 coating’, J. Adv. Mater. Proc., 2014,
2, 25–32.
14.
ShettyD. K., WrightI. G., MincerP. N. and ClauerA. H.: ‘Indentation fracture of WC-Co cermets’, J. Mater. Sci.,
20, 1985, 1873–1882. doi: 10.1007/BF00555296
ChenC. Y. and HwangW. S.: ‘Effect of annealing on the interfacial structure of aluminum-copper joints’, Mater. Trans., 2007,
48, 1938–1947. doi: 10.2320/matertrans.MER2006371
17.
SauthoffG.: ‘Intermetallics’, 2008, New York
, Wiley-VCH.
18.
VarinR. A., ZbroniecL., CzujkoT. and SongY. K.: ‘Fracture toughness of intermetallic compacts consolidated from nanocrystalline powders’, Mater. Sci. Eng. A, 2001,
300, 1–11. doi: 10.1016/S0921-5093(00)01809-8
19.
FontanaM. G.: ‘Corrosion engineering’, 3rd edn, 1997, New York
, McGraw-Hill.
20.
BarsoukovE. and MacdonaldJ. R.: ‘Impedance spectroscopy theory, experiment, and applications’, 2nd edn, 2005, New York
, John Wiley & Sons.
21.
ZhangQ. and ZhonghuaZ.: ‘On the electrochemical dealloying of Al-based alloys in a NaCl aqueous solution’, Phys. Chem. Chem. Phys., 2010,
12, 1453–1472. doi: 10.1039/B919313H
