Abstract
Mg alloy AZ31 was spray-formed using an indigenously developed spray atomisation and deposition unit under protective atmosphere and various processing parameters were optimised. The microstructural features of the bell shaped AZ31 spray-formed deposit were characterised using optical microscope, scanning electron microscope/energy dispersive spectrometer, X-ray diffraction and high resolution transmission electron microscope. It was observed that the microstructural features are critically dependent on location in the spray-formed deposits. Under optimised processing conditions, the central region of the bell shaped deposit exhibited minimal porosity and a uniform fine grained equiaxed microstructure with fine Mg17Al12 intermetallics preferably located at the grain boundaries. However, the peripheral regions of the spray-formed deposit indicate higher porosity with distinct microstructural characteristics different from those in the central region. These microstructural features, observed at different locations in the spray-formed deposit, have been analysed and their evolution is discussed in the light of variations in thermal and solidification conditions of the droplets in flight, during impingement as well as those of the deposition surface.
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