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 hypereutectic 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 VPS 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.