Effect of SiC particle size on cold sprayed Al–SiC composite coatings

Abstract

Al–SiC composites as well as pure Al were prepared on Si and Al substrate by cold spray. The powder composition of metal (Al) and ceramic SiC was varied into 1 : 1 and 10 : 1 (vol.-%) respectively. SiC with various particle sizes has been successfully coated with the soft metal of Al. Also, when the large SiC particles were coated with Al, the hard ceramic particles showed a high velocity impact on the substrate surfaces. In the case of pure Al metal coating, there was no crater formation on hard Si substrate. However, in the composite coatings with large SiC particles, the craters were observed at the interface between the coatings and Si substrate and it was also found that depth and sizes of craters depended on the size of SiC raw materials.