Abstract
In this study, Al-based composite coatings reinforced with Al-Fe intermetallic were prepared by ultra-fast Joule heating of cold-sprayed Al coatings on AISI 1045 steel. The plate Fe2Al5 was formed both at the Al-Fe interface and within the cold-sprayed Al coating. It is proposed that both the ultra-fast Joule heating and the unique defects distribution within the cold-sprayed coating were responsible for the formation of Fe2Al5 in the cold sprayed Al coatings. After the ultra-fast Joule heating, the more severely deformed regions in the cold-sprayed coatings had higher Fe concentration, which promoted the formation of Fe2Al5 in these areas. The in-situ formation of Fe2Al5 greatly improves the microhardness and wear resistance of the cold-sprayed Al coating.
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