Abstract
Abstract The high velocity oxy-liquid fuel (HVOLF) thermal spray technique has the potential to fabricate thick layers based on the Al–12 wt.% Sn–1 wt.% Cu alloy. The microstructure of the as-sprayed coatings exhibits several levels of complexity due to the effects of rapid quenching and metastable phase formation. The use of tripod polishing and low angle milling procedures have allowed the sectioning of large thin areas of material for plan view and cross-sectional transmission electron microscope (TEM) observation, thereby clearly delineating regions of material that have undergone differing patterns of melting and freezing during the HVOLF process. Comparison has also been made with the pre-sprayed gas-atomised powder. The microstructure of most of the larger gas-atomised powder particles comprises Al dendrites surrounded by Sn interdendrite phase. Conversely,
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