Ci a ion: Villanue a, E.; Vica io, I.;
Vaque o, C.; Albizu i, J.; Gu aya, M.T.;
Bu gos, N.; Hu ado, I. S udy o a
New No el HVOAF Coa ing Based
on a New Mul icomponen
Al80Mg10Si5Cu5 Alloy. Coa ings 2024,
14, 1135. h ps://doi.o g/10.3390/
coa ings14091135
Academic Edi o s: Nadia A ousse
and Hamza Ichou
Recei ed: 5 Augus 2024
Re ised: 29 Augus 2024
Accep ed: 2 Sep embe 2024
Published: 4 Sep embe 2024
Copy igh : © 2024 by he au ho s.
Licensee MDPI, Basel, Swi ze land.
This a icle is an open access a icle
dis ibu ed unde he e ms and
condi ions o he C ea i e Commons
A ibu ion (CC BY) license (h ps://
c ea i ecommons.o g/licenses/by/
4.0/).
coa ings
A icle
S udy o a New No el HVOAF Coa ing Based on a New
Mul icomponen Al80Mg10Si5Cu5 Alloy
Es e Villanue a 1,* , Iban Vica io 1, Ca los Vaque o 1, Joseba Albizu i 2, Ma ia Te esa Gu aya 2,
Ne ea Bu gos 3and Iñaki Hu ado 4
1Me al P ocessing Pla o m, TECNALIA Resea ch & Inno a ion, Basque Resea ch and Technology
Alliance (BRTA), E48160 De io, Spain; [email p o ec ed] (I.V.); [email p o ec ed] (C.V.)
2Depa men o Mechanical Enginee ing and Me allu gy, Uni e si y o he Basque Coun y (UPV/EHU),
E48013 Bilbao, Spain; [email p o ec ed] (J.A.); [email p o ec ed] (M.T.G.)
3Di ision o Ma e ials & Manu ac u ing, CEIT-IK4, Basque Resea ch and Technology Alliance (BRTA),
E20018 Donos ia-San Sebas ian, Spain; [email p o ec ed]
4Mechanical and Manu ac u ing Depa men , Mond agon Uni e si y, E20500 A asa e-Mond agon, Spain;
[email p o ec ed]
*Co espondence: es e [email p o ec ed]
Abs ac : This pape p esen s and demons a es he de elopmen o a new ligh weigh coa ing o
aluminum alloy om a no el mul icomponen alloy based on he AlSiMgCu sys em. The coa ing
was applied using a newly designed app oach ha combined high eloci y oxy- uel (HVOF) and
plasma sp aying p ocesses. This hyb id echnique enables he deposi ion o coa ings wi h enhanced
pe o mance cha ac e is ics. The op ical mic oscopy (OM) and scanning elec on mic oscopy wi h
ene gy dispe si e X- ay spec oscopy (SEM + EDS) e ealed a s ong adhesion and compac ion
be ween he mul icomponen coa ing and he A6061 subs a e. The new coa ing imp o ed ha dness
by 50% and inc eased elec ical conduc i i y by app oxima ely 3.3 imes compa ed o he as-cas
alloy. Co osion es s showed a lowe co osion a e, compa able o he mally ea ed A6061 alloy.
T ibological es s indica ed o e 20% educ ion in ic ion and o e 50% educ ion in wea a e.
This sugges s ha mul icomponen aluminum coa ings could imp o e au omo i e and pa s in
con ac wi h hyd ogen by enhancing hyd ogen agiliza ion esis ance, co osion esis ance, elec ical
conduc i i y, and wea p ope ies, wi h u he op imiza ion o he mal sp aying po en ially boos ing
pe o mance e en u he .
Keywo ds: coa ing; plasma; HVOF; mul icomponen aluminum alloy; wea ; elec ical conduc i i y;
ha dness; mic os uc u e
1. In oduc ion
P o ec i e coa ings ha e p o en a high e ec i i y in ex ending he li espan o me allic
s uc u es and in mul iple sec o s, including au oma ion pa s, wi h he ecen end o
employ aluminum ins ead o s eel due o i s uel economy bene i s [
1
]. These coa ings
include pain s, o ganic and ino ganic coa ings, di usion laye s, me allic coa ings, and
gal aniza ion [
2
]. The mal sp ay is a highly e sa ile echnology o ob ain ce amic and
me allic coa ings sui able o a ious applica ions and componen s. I is e ec i e agains
wea , co osion, and ha sh high- empe a u e en i onmen s, and i enhances he mal e -
iciency, such as h ough insula ion in aluminum engine cylinde s [
3
]. Addi ionally, i is
ideal o he epai and es o a ion o componen s [4].
Wi hin he he mal sp ay echniques, se e al p ocesses a e no ewo hy, including cold
sp ay [
4
], HVOF, win wi e a c sp aying, powde o de ona ion lame sp aying, a mosphe ic
plasma sp aying, and a c sp aying [
5
]. These me hods di e in hei applica ion echniques,
such as he o m o eeds ock, ma e ial gene a ion, anspo medium eloci y, anspo
medium empe a u e, and he unique p ope ies hey impa .
Coa ings 2024,14, 1135. h ps://doi.o g/10.3390/coa ings14091135 h ps://www.mdpi.com/jou nal/coa ings
Coa ings 2024,14, 1135 2 o 22
Among he ad anced he mal sp ay echniques, HVOF echnology s ands ou . This
inno a i e me hod employs a combus ion sys em wi h high-p essu e uel and oxidize
gases o induce a de ona ion wi hin he combus ion chambe . This p ocess pa ially o
ully mel s he ma e ial, accele a ing i o adhe e e ec i ely o he subs a e. The esul
is a high- eloci y luid haze wi h empe a u es eaching up o 3000
◦
C and supe sonic
speeds anging be ween 400 and 1.000 m/s [
6
,
7
]. By op imizing pa ame e s, such as he
uel and oxygen low a e, powde eed a e [
8
], sp ay dis ance, and ca ie gas low a e, i
is possible o p oduce compac coa ings wi h excellen esis ance o ab asion, hea , ic ion,
and wea [
9
–
11
]. No ably, he mally sp ayed coa ing wi h a hickness o jus 1 mm can
achie e ha dness alues up o 2000 HV [12].
Po osi y, which in luences co osion alongside nanoc ys alline amo phous phases and
he ha dness o he coa ing, will depend on he oxygen low a e ollowed by he powde
eed a e and sp ay dis ance [
13
]. The sp ay dis ance will also a ec he phase deg ada ion,
deposi ion e iciency, and bonding s eng h [
9
]. Addi ionally, he angle o incidence impac s
he inal p ope ies, wi h a highe p ehea ing empe a u e and a lowe angle o incidence
enhancing he co osion esis ance o coa ings [
14
]. Also, gun speed can be impo an in he
inal p ope ies o he coa ing. Fas e gun mo emen educes o ch dwell ime, sp aying
less powde and lowe ing he coa ing empe a u e [15].
Compa ed o o he he mal sp ay p ocesses, HVOF coa ings o e supe io su ace
quali y [
13
]. Addi ionally, when compa ed o o he high-pe o mance echniques such
as a mosphe ic plasma sp aying (APS), HVOF educes he he mal deg ada ion o he
ma e ial [16].
Ce ain s udies ha e epo ed he applica ion o HVOF echniques on aluminum alloy
subs a es [
17
–
22
], using ce amic ma e ials such as ca bides and oxides as he p ima y
coa ing ma e ial due o hei high mel ing poin s. In some cases, ca bides and oxides a e
combined wi h me als such as Co, Ni, and C o achie e a low oxygen con en and excellen
adhesion p ope ies [23].
The applica ion o a WC10Co4C coa ing on an aluminum subs a e esul ed in educed
mechanical p ope ies [
24
]. Addi ionally, du ing ic ion es s, he ca bide pa icles caused
ab asion and agmen a ion o he coa ing laye s. The e inemen o he mic os uc u e,
in luenced by he eeds ock powde s, and he educ ion o po osi y led o an inc ease
in ha dness om 68 HV up o 920 HV in he C
3
C
2
he mal sp ay coa ing on an Al-Si
subs a e [
25
]. Ano he s udy [
26
] demons a ed ha an alumina coa ing up o 150
µ
m hick
o e an A6061 alloy esul ed in ha dness alues en imes highe han he base. Du ing
he ic ion es , he subs a e exhibi ed an ab asion wea mechanism wi h a seconda y
adhesion mechanism, causing se e e plas ic de o ma ion and delamina ion, while he
coa ing laye showed some c acks bu no sc a ches o g oo es, which a e cha ac e is ics o
ab asion wea . On AlZn5.5MgCu aluminum alloy, AlCuFe quasic ys al was deposi ed as a
coa ing [
27
], showing ic ion coe icien alues be ween 0.92 and 1.00. Fo A390 aluminum
alloys, he Al
2
O
3
coa ing showed lowe adhesion and an uns able ic ion beha io , wi h
a dynamic coe icien o ic ion o 0.8, compa ed o a ound 0.6 o he WC-based coa ing.
Ha dness alues exceeded 1000 HV o WC-based coa ings, while Al
2
O
3
-base coa ings
eached 315 HV. Ab asion and adhesion wea mechanisms we e obse ed in all cases [
28
].
Combining Al
2
O
3
wi h Y
2
O
3
and TiO
2
in coa ings has been epo ed o u he enhance
wea p ope ies [29].
Some s udies ha e explo ed aluminum-based coa ing on aluminum subs a es, bu
he e is limi ed in o ma ion on he wea cha ac e is ics o ce amic and me allic coa ing
on aluminum alloys, especially o au omo i e applica ions. A no ewo hy a icle [
30
]
discusses he use o a Ni-SiC-based composi e on A356 aluminum alloy, which is commonly
used in au omobile cylinde s and machine ool sha s. Unde non-lub ica ing condi ions,
he ic ion coe icien a e aged 0.55, and he wea a e anged om 16
×
10
−4
mm
3
/N
·
m
o 39
×
10
−4
mm
3
/N
·
m. The wea mechanism in ol ed bo h ab asion and delamina ion.
In a lub ica ing en i onmen , he coe icien o ic ion was educed by a ac o o 5, and he
wea a e was 10 imes lowe compa ed o d y ic ion. The addi ion o se ici e imp o ed
Coa ings 2024,14, 1135 3 o 22
he wea a e o 2024 aluminum alloy [
31
]; howe e , his alloy is p ima ily used in ai c a
s uc u es. O he alloys, such as i anium alloys (Ti6Al4V), ha e employed ce amic coa ings
such as TiC [
32
], which ipled wea esis ance, al hough hese alloys a e mainly used in
biological applica ions.
I has been demons a ed ha me als such as aluminum a e also bene icial o coa ing
echnologies, c ea ing new demands o su ace p e- ea men coa ings o co osion p o-
ec ion and pain adhesion in he au omo i e sec o [
33
]. A no able ecen de elopmen is
he Alcoa p ojec , which ocuses on c ea ing a new ecycled aluminum coa ing o s eel
p oduc s [34].
A cu en end and eme ging oppo uni y ha has ga ne ed signi ican esea ch
a en ion o e he pas decade is he p oduc ion o high en opy alloys (HEAs), also
known as composi ional complex alloys (CCAs) and mul icomponen alloys [
35
]. The
dis inc i eness o hese new alloys lies in hei subs an ial imp o emen in mechanical
p ope ies. One o he undamen al concep s is o achie e a mo e diso de ed s uc u e wi h
i e o mo e elemen s a o nea equimola composi ion, o ming a solid solu ion phase, in
con as o con en ional alloys, which a e based on he cen al a eas o phase diag ams [
36
].
Despi e hese new oppo uni ies and hei excellen mechanical p ope ies [
37
,
38
], he
la ge-scale p oduc ion o Ligh High En opy Alloys (LWHEAs) is limi ed, wi h acuum
die cas ing being he p ima y manu ac u ing p ocess [
39
]. In some special cases, he
in es iga ed alloys include expensi e elemen s such as Ag, which inc eases ha dness and
yield s eng h by mo e han 10% and elonga ion by 21% [
40
], o Nb [
41
]. Howe e , he
addi ion o hese elemen s esul s in non-cos -e ec i e alloys. Recen ly, i has been epo ed
ha apid solidi ica ion p ocesses can enhance he single-phase mic os uc u es in hese
alloys wi h he absence o a dend i ic mic os uc u e [
42
], al hough, in some ins ances, his
equi emen is no me , esul ing p edominan ly in in e me allic phases [
43
]. New s udies
ha e demons a ed ha , despi e he limi ed unde s anding o in e me allics in HEA alloys,
hey can ac as e y e ec i e seconda y phases [44].
The de elopmen o mul i-componen ma e ials based on aluminum alloys holds
p omise. Aluminum ma ix composi e b ake d ums and o o s ha e been used in ehicles
such as he Lo us Elise, Volkswagen Lupo 3L, Ch ysle Plymou h P owle , and Gene al
Mo o s EV-1 due o hei he mal and wea p ope ies [45].
The use o HVOF echnology is limi ed due o economic easons s emming om
ela i ely expensi e equipmen and ope a ional cos s, pa icula ly o aw ma e ial pow-
de s [
46
]. F om his pe spec i e, employing seconda y aluminum alloys o he mal sp ay
powde s could yield cos -e ec i e esul s.
In his esea ch, a new he mal sp ay p ocess combining HVOF and plasma echnolo-
gies is employed. This new de ice u ilizes a he mal plasma o enhance he combus ion
p ocess wi hin he HVOF sp ay o ch and inco po a es an auxilia y cold gas o assis in
con olling he p ocess empe a u e. The use o he mal plasma o assis combus ion aims
o inc ease he lexibili y o he sp ay sys em in e ms o ope a ing pa ame e s and he
ange o ma e ials ha can be sp ayed [47].
As he aw ma e ial g ain size in luences he inal mechanical p ope ies, gas a om-
iza ion has been selec ed as he me hod o con e a new mul icomponen cas alloy in o
powde . This p ocess p o ides g ain sizes anging om 10
µ
m o 150
µ
m [
48
]. Mo eo e ,
he alloy has been manu ac u ed using he High-P essu e Die-Cas ing (HPDC) p ocess,
which also p oduces smalle g ain sizes ha a e a o able o a omiza ion [49].
I is no ewo hy ha due o oxida ion, accele a ed by p ocess empe a u es, hese
coa ings can se e as e ec i e he mal ba ie coa ings o componen s exposed o ho
gases. This cha ac e is ic ende s hem sui able o anspo a ion applica ions. One o
he p ope ies o some mul icomponen alloys is he capabili y o a oiding hyd ogen
agiliza ion in me als, so hey can also be in e es ing o hyd ogen u iliza ion [50,51].
Coa ings 2024,14, 1135 4 o 22
2. Ma e ials and Me hods Expe imen al
2.1. Ma e ials Subs a e and Coa ing
A new mul icomponen aluminum alloy based on he Al80Mg10Si5Cu5 sys em was
used in he expe imen al s udy. This new alloy was ob ained by he HPDC ound y
p ocess, in ol ing high solidi ica ion speeds, and p omo es mic os uc u es wi h supe io
mechanical p ope ies [
52
]. The ini ial as-cas condi ion phases included he aluminum
ma ix, p ima y and eu ec ic Mg
2
Si pa icles o a ound 20 and 5
µ
m, espec i ely, and
coppe - ich phases (Al2Cu and Al2CuMg) wi h sizes a ound 10 µm.
The Al80Mg10Si5Cu5 alloy was con e ed in o powde by gas a omiza ion wi h a
Leybold VIGA 2S a omize (Leybold p oduc s, Co nellàde Llob ega , Spain) wi h A gon
a a p essu e o 2.4 MPa, and he mel empe a u e was se a 850
◦
C. Subsequen ly, a
quali a i e and semiquan i a i e analysis was pe o med by a e aging he composi ion
om h ee measu emen s, each co e ing o e 100 pa icles. Figu e 1illus a es he i egula
mo phology o he powde ob ained a e a omiza ion.
Coa ings 2024, 14, x FOR PEER REVIEW 4 o 23
2. Ma e ials and Me hods Expe imen al
2.1. Ma e ials Subs a e and Coa ing
A new mul icomponen aluminum alloy based on he Al80Mg10Si5Cu5 sys em was
used in he expe imen al s udy. This new alloy was ob ained by he HPDC ound y p o-
cess, in ol ing high solidi ica ion speeds, and p omo es mic os uc u es wi h supe io
mechanical p ope ies [52]. The ini ial as-cas condi ion phases included he aluminum
ma ix, p ima y and eu ec ic Mg
2
Si pa icles o a ound 20 and 5 µm, espec i ely, and
coppe - ich phases (Al
2
Cu and Al
2
CuMg) wi h sizes a ound 10 µm.
The Al80Mg10Si5Cu5 alloy was con e ed in o powde by gas a omiza ion wi h a
Leybold VIGA 2S a omize (Leybold p oduc s, Co nellà de Llob ega , Spain) wi h A gon
a a p essu e o 2.4 MPa, and he mel empe a u e was se a 850 °C. Subsequen ly, a
quali a i e and semiquan i a i e analysis was pe o med by a e aging he composi ion
om h ee measu emen s, each co e ing o e 100 pa icles. Figu e 1 illus a es he i eg-
ula mo phology o he powde ob ained a e a omiza ion.
Figu e 1. SEM image o he mic os uc u e o Al80Mg10Si5Cu5 powde a ×1000 and ×4000 magni-
ica ions.
Finally, be o e he mul icomponen ma e ial he mal sp aying on he subs a e, a
sie ing p ocess was ca ied ou wi h an op imum a ge size dis ibu ion be ween 63 and
250 µm in 4 uns.
As pa o he ma e ial subs a e, a comme cially ex uded A6061 aluminum alloy
was employed. This alloy is commonly used in componen s o he au omo i e indus y
[53]. Comme cial pla es wi h dimensions o 40 mm × 30 mm and a hickness o 5 mm we e
used. Be o e he coa ing p ocess, he samples we e g ound up o 800 g i wi h SiC pape ,
cleaned wi h p opanol, and inally d ied. Table 1 collec s he chemical composi ion and
Table 2 he mechanical, elec ical, and he mal p ope ies o he wo expe imen al alloys.
Table 1. Chemical composi ion o expe imen al alloys in %w .
Alloy Al Mg Si Cu Mn Fe Zn
Al80Mg10Si5Cu5 78.9 10.3 5.6 4.7 0.1 0.3 0.1
A6061 98.2 0.9 - 0.9 - - -
Table 2. Mechanical, elec ical, and he mal p ope ies o expe imen al alloys.
Alloy Ha dness (HV3)
Elec ical Conduc i i y
(%IACS) Mel ing Poin (°C)
Al80Mg10Si5Cu5 130 ± 13.01 17 ± 0.55 592
A6061 68 ± 4.17 57 ± 0.41 585
Figu e 1. SEM image o he mic os uc u e o Al80Mg10Si5Cu5 powde a
×
1000 and
×
4000 magni ica ions.
Finally, be o e he mul icomponen ma e ial he mal sp aying on he subs a e, a
sie ing p ocess was ca ied ou wi h an op imum a ge size dis ibu ion be ween 63 and
250 µm in 4 uns.
As pa o he ma e ial subs a e, a comme cially ex uded A6061 aluminum alloy was
employed. This alloy is commonly used in componen s o he au omo i e indus y [
53
].
Comme cial pla es wi h dimensions o 40 mm
×
30 mm and a hickness o 5 mm we e used.
Be o e he coa ing p ocess, he samples we e g ound up o 800 g i wi h SiC pape , cleaned
wi h p opanol, and inally d ied. Table 1collec s he chemical composi ion and Table 2 he
mechanical, elec ical, and he mal p ope ies o he wo expe imen al alloys.
Table 1. Chemical composi ion o expe imen al alloys in %w .
Alloy Al Mg Si Cu Mn Fe Zn
Al80Mg10Si5Cu5 78.9 10.3 5.6 4.7 0.1 0.3 0.1
A6061 98.2 0.9 - 0.9 - - -
Table 2. Mechanical, elec ical, and he mal p ope ies o expe imen al alloys.
Alloy Ha dness (HV3) Elec ical Conduc i i y
(%IACS) Mel ing Poin (◦C)
Al80Mg10Si5Cu5 130 ±13.01 17 ±0.55 592
A6061 68 ±4.17 57 ±0.41 585
Coa ings 2024,14, 1135 5 o 22
2.2. Plasma Coa ing
A newly designed, sel -manu ac u ed sys em employing he HVOAF echnology, a
combina ion o HVOF and plasma, was employed o coa he p epa ed A6061 aluminum
alloy. This sys em, named Kombus+, was enginee ed and p oduced by Tecnalia. The
Kombus + sys em is based on a supe sonic combus ion p ojec ion sys em wi h oxygen and
ai . The mix u e o gas + ai /O
2
inc eases lows o main ain supe sonic speed and p essu e.
Figu e 2illus a es he plasma equipmen wi h he obo applying a coa ing o a sample.
Coa ings 2024, 14, x FOR PEER REVIEW 5 o 23
2.2. Plasma Coa ing
A newly designed, sel -manu ac u ed sys em employing he HVOAF echnology, a
combina ion o HVOF and plasma, was employed o coa he p epa ed A6061 aluminum
alloy. This sys em, named Kombus+, was enginee ed and p oduced by Tecnalia. The
Kombus + sys em is based on a supe sonic combus ion p ojec ion sys em wi h oxygen and
ai . The mix u e o gas + ai /O2 inc eases lows o main ain supe sonic speed and p essu e.
Figu e 2 illus a es he plasma equipmen wi h he obo applying a coa ing o a sample.
The expe imen al pa ame e s we e speci ied: he uel low a e was calib a ed o 380
L pe min, wi h me hane as he uel gas because i s maximum lame empe a u e [54]
helped o educe gas consump ion and allowed he use o a uel wi h a ela i ely low g oss
hea ing alue [47].
The oxygen low a e was se o 300 L pe min, while he ai low was egula ed a
1500 L pe min wi h an ai p essu e o 14 ba . The ca ie low was adjus ed o 90 li e s
pe min, and he powde eed a e was se o 25% wi h a 90-deg ee incidence angle. The
sp ay gun was posi ioned 300 mm om he subs a e, mo ing a 0.9 m pe second. The
sys em ope a ed a 250 e olu ions pe min.
These pa ame e s ha e been selec ed based on accumula ed expe ience [55–57] and
as equipmen manu ac u e s [58], which de e mined ha hey we e he mos op imal o
aluminum alloys. They a e conside ed ‘cold’ pa ame e s due o he low mel ing poin o
he new mul i-componen aluminum alloy compa ed wi h o he coa ing ma e ials such as
WC [59].
Figu e 2. Plasma p ojec ing wi h he obo .
When measu ed wi h a py ome e , he lame empe a u e eached 2000 °C while he
subs a e empe a u e was eco ded a 200 °C.
2.3. Mic os uc u al Analysis
The mic os uc u e o he alloys was s udied using a Leica DMI5000M op ical mic o-
scope (LEICA, We zla , Ge many) and an EI Quan a 450 scanning elec on mic oscopy
(SEM) wi h Ene gy Dispe si e Spec oscopy (EDX) analysis. The composi ion o he alloy
p oduced by HPDC was de e mined using X- ay di ac ion (XRD) wi h a Philips X’Pe
P o MPD PW3040/60 di ac ome e (Mal e n Panaly ical L d., Mal e , UK), equipped
wi h a coppe anode ope a ing a 40 kV and 40 mA (1.6 kW). Scans we e pe o med in a
Figu e 2. Plasma p ojec ing wi h he obo .
The expe imen al pa ame e s we e speci ied: he uel low a e was calib a ed o
380 L pe min
, wi h me hane as he uel gas because i s maximum lame empe a u e [
54
]
helped o educe gas consump ion and allowed he use o a uel wi h a ela i ely low g oss
hea ing alue [47].
The oxygen low a e was se o 300 L pe min, while he ai low was egula ed a
1500 L pe min wi h an ai p essu e o 14 ba . The ca ie low was adjus ed o 90 li e s pe
min, and he powde eed a e was se o 25% wi h a 90-deg ee incidence angle. The sp ay
gun was posi ioned 300 mm om he subs a e, mo ing a 0.9 m pe second. The sys em
ope a ed a 250 e olu ions pe min.
These pa ame e s ha e been selec ed based on accumula ed expe ience [
55
–
57
] and
as equipmen manu ac u e s [
58
], which de e mined ha hey we e he mos op imal o
aluminum alloys. They a e conside ed ‘cold’ pa ame e s due o he low mel ing poin o
he new mul i-componen aluminum alloy compa ed wi h o he coa ing ma e ials such as
WC [59].
When measu ed wi h a py ome e , he lame empe a u e eached 2000
◦
C while he
subs a e empe a u e was eco ded a 200 ◦C.
2.3. Mic os uc u al Analysis
The mic os uc u e o he alloys was s udied using a Leica DMI5000M op ical mic o-
scope (LEICA, We zla , Ge many) and an EI Quan a 450 scanning elec on mic oscopy
(SEM) wi h Ene gy Dispe si e Spec oscopy (EDX) analysis. The composi ion o he alloy
p oduced by HPDC was de e mined using X- ay di ac ion (XRD) wi h a Philips X’Pe
P o MPD PW3040/60 di ac ome e (Mal e n Panaly ical L d., Mal e , UK), equipped
wi h a coppe anode ope a ing a 40 kV and 40 mA (1.6 kW). Scans we e pe o med in a 2
θ
ange om 10
◦
o 90
◦
, wi h a s ep size o 0.02
◦
2
θ
and a du a ion o 2 s pe s ep. The X- ay
Coa ings 2024,14, 1135 6 o 22
di ac ion pa e ns we e indexed wi h he PDF-2 da abase om he In e na ional Cen e
o Di ac ion Da a (ICDD).
2.4. Ha dness S udy
Vicke s inden a ions we e employed o e alua e he ha dness o he new ma e ial
wi h he coa ing. The Vicke s ha dness was de e mined using a Vicke s ha dness es e
model FV-700 (Mi u oyo, Kawasaki, Japan), selec ing a e se e al ials he load o 10 kg
as he bes op ion. Measu emen s we e aken a he op, bo om, and in e ace a eas o he
coa ing. Addi ionally, ha dness measu emen s we e aken on he subs a e o ensu e ha
he he mal p ocess did no a ec he mechanical p ope ies o he base ma e ial. In o al,
3 samples we e analyzed.
2.5. D y Sliding Wea Beha io
To in es iga e he ibological p ope ies o he new coa ed aluminum alloy, d y sliding
wea ic ion es s we e conduc ed using a sphe e-on-pla e ecip oca ing con igu a ion wi h
a ball-on-disk (BOD) se up, ollowing ASTM G99-05 s anda d wi hou any lub ican . Tes s
we e pe o med using a ibome e (MT2/60/NI/HT, Mic o es S.A., Mad id, Spain). A
o al o 6 es s we e pe o med: 3 es s on he coa ed ma e ial and ano he 3 on he subs a e
wi hou he coa ing.
The es ing pa ame e s employed du ing he sliding wea ic ion es s a e summa ized
in Table 3. The selec ion o hese pa ame e s aligns wi h ibological s udies conduc ed on
o he high-wea pe o mance aluminum alloys [60].
Table 3. Sliding wea es pa ame e s.
Tes Pa ame e s Selec ed Value
Load (N) 15.0
Veloci y (m/s) 0.1
Ro a ion speed ( pm) 127.3
Sliding dis ance (m) 500.0
T ack diame e (mm) 15
En i onmen D y ai
Alumina balls wi h a diame e o 6 mm and ha dness alues anging be ween 1250
and 1700 HV we e used as coun e - ace bodies. The use o alumina sphe es as a coun e ace
ensu es ha he mechanically mixed laye (MML), which is common when s eel balls a e
used and ypically con ains Al-Fe-O, is no o med. This minimizes chemically d i en
aspec s o adhesi e wea due o educed chemical adhesion [
61
], he eby acili a ing he
de e mina ion o wea p ope ies [62].
A e comple ing he BOD es s, he de e mina ion o he wea coe icien a e was
conduc ed using 3D lase scanning con ocal mic oscopy (DCM 3D, Leica, Mad id, Spain).
A o al a ea o 20.8 mm
×
20.2 mm and a heigh o 684
µ
m we e measu ed using a 5X
objec i e. A leas 16 2D p o iles we e ob ained using Leica map so wa e e sion 3.2.
Addi ionally, o compa ison, ou adii o 2.5 mm
×
1.8 mm and a heigh o 275
µ
m we e
measu ed using he same 5X objec i e. The o al olume loss was calcula ed, and wea
coe icien s we e ob ained in mm3/N·m [63,64].
Images o he wea ack and c oss-sec ions o he wea acks we e cap u ed and
analyzed o iden i y he wea mechanisms, using op ical mic oscopy (OM), scanning
elec on mic oscopy (SEM), and con ocal mic oscopy (CM).
2.6. Elec ical Conduc i i y
The elec ical conduc i i y (EC) was assessed wi h a po able conduc i i y me e , an
Au osigma 3000 model (Jess W Jackson & Assoc., Bu o d, GA, USA). This de ice employs
Coa ings 2024,14, 1135 7 o 22
he Eddy Cu en me hod o gauge conduc i i y and epo s he esul s in he s anda d
uni o %IACS (In e na ional Annealed Coppe S anda d). Conduc i i y measu emen s
we e pe o med on he newly coa ed ma e ial, wi h a minimum o i e eadings aken om
he sample.
2.7. Co osion Tes
The gene al co osion a e was de e mined using elec ochemical echniques. Two
di e en expe imen s, elec ochemical impedance spec oscopy (EIS) and po en iodynamic
pola iza ion in he TAFEL egion, we e conduc ed on he new as-cas mul icomponen
Al80Mg10Si5Cu5 alloy. The combined use o hese wo echniques has been epo ed in
some s udies as an al e na i e o a oid p ac ical issues ha o en educe hei eliabili y [
65
].
The es s we e pe o med in a 3.5 w .% sodium chlo ide solu ion. Be o e each es , he
samples we e g inded and s abilized o open ci cui po en ial (OCP) o 60 min, adhe ing
o ASTM G5 guidelines.
3. Resul s
3.1. Mic os uc u e o New Al80Mg10Si5Cu5 Coa ing on A6061 Alloy
The XRD analysis o he new mul icomponen alloy ob ained by HPDC wi h high
cooling a es is p esen ed in Figu e 3. As shown, he alloy exhibi ed ou phases: an
aluminum ma ix, Mg2Si, Al2Cu, and Al2CuMg.
Coa ings 2024, 14, x FOR PEER REVIEW 7 o 23
2.6. Elec ical Conduc i i y
The elec ical conduc i i y (EC) was assessed wi h a po able conduc i i y me e , an
Au osigma 3000 model (Jess W Jackson & Assoc., Bu o d, GA, USA). This de ice employs
he Eddy Cu en me hod o gauge conduc i i y and epo s he esul s in he s anda d
uni o %IACS (In e na ional Annealed Coppe S anda d). Conduc i i y measu emen s
we e pe o med on he newly coa ed ma e ial, wi h a minimum o i e eadings aken
om he sample.
2.7. Co osion Tes
The gene al co osion a e was de e mined using elec ochemical echniques. Two
di e en expe imen s, elec ochemical impedance spec oscopy (EIS) and po en iody-
namic pola iza ion in he TAFEL egion, we e conduc ed on he new as-cas mul icompo-
nen Al80Mg10Si5Cu5 alloy. The combined use o hese wo echniques has been epo ed
in some s udies as an al e na i e o a oid p ac ical issues ha o en educe hei eliabili y
[65]. The es s we e pe o med in a 3.5 w .% sodium chlo ide solu ion. Be o e each es ,
he samples we e g inded and s abilized o open ci cui po en ial (OCP) o 60 min, ad-
he ing o ASTM G5 guidelines.
3. Resul s
3.1. Mic os uc u e o New Al80Mg10Si5Cu5 Coa ing on A6061 Alloy
The XRD analysis o he new mul icomponen alloy ob ained by HPDC wi h high
cooling a es is p esen ed in Figu e 3. As shown, he alloy exhibi ed ou phases: an alu-
minum ma ix, Mg
2
Si, Al
2
Cu, and Al
2
CuMg.
Figu e 3. XRD analysis o Al80Mg10Si5Cu5 ob ained by HPDC.
Following, Figu e 4 shows he SEM images o he coa ed A6061 aluminum ma e ial
wi h he Al80Mg10Si5Cu5 mul icomponen alloy. Images e ealed ha he new coa ing
achie ed hicknesses anging om 50 o 130 µm, hough i was no comple ely homoge-
neous. The hickness o he de eloped coa ings alls wi hin he ypical ange ob ained by
he mal sp ayed echniques (100–500 µm) [66], wi h he powde eed a e as he main
pa ame e ha in luences he deposi ion a e, de e mining whe he i is low o high [67].
EDS analysis, as p esen ed in Table 4, indica ed ha while he new mul icomponen
alloy in i s as-cas s a e exhibi ed ou phases, he new coa ing displayed only wo dis inc
phases. To con i m, he composi ion o each o he obse ed phases was analyzed and
compa ed wi h li e a u e da a [68–70].
Figu e 3. XRD analysis o Al80Mg10Si5Cu5 ob ained by HPDC.
Following, Figu e 4shows he SEM images o he coa ed A6061 aluminum ma e ial
wi h he Al80Mg10Si5Cu5 mul icomponen alloy. Images e ealed ha he new coa ing
achie ed hicknesses anging om 50 o 130
µ
m, hough i was no comple ely homoge-
neous. The hickness o he de eloped coa ings alls wi hin he ypical ange ob ained
by he mal sp ayed echniques (100–500
µ
m) [
66
], wi h he powde eed a e as he main
pa ame e ha in luences he deposi ion a e, de e mining whe he i is low o high [67].
EDS analysis, as p esen ed in Table 4, indica ed ha while he new mul icomponen
alloy in i s as-cas s a e exhibi ed ou phases, he new coa ing displayed only wo dis inc
phases. To con i m, he composi ion o each o he obse ed phases was analyzed and
compa ed wi h li e a u e da a [68–70].
The p ima y phase co esponds o he aluminum ma ix, appea ing in g ay (poin 2).
Ligh g ay a eas en iched wi h Mg, Si, and Cu (poin 3) we e obse ed and co ela ed wi h
he aluminum ma ix wi h Mg
2
Si and pa o Al
2
Cu phases. Addi ionally, whi e-colo ed
phases we e co ela ed wi h Al
2
CuMg phases wi h a spla pa e n-like s uc u e [
29
] a he
g ain bounda ies o he aluminum ma ix (poin 4).
Coa ings 2024,14, 1135 8 o 22
Coa ings 2024, 14, x FOR PEER REVIEW 8 o 23
The p ima y phase co esponds o he aluminum ma ix, appea ing in g ay (poin 2).
Ligh g ay a eas en iched wi h Mg, Si, and Cu (poin 3) we e obse ed and co ela ed wi h
he aluminum ma ix wi h Mg
2
Si and pa o Al
2
Cu phases. Addi ionally, whi e-colo ed
phases we e co ela ed wi h Al
2
CuMg phases wi h a spla pa e n-like s uc u e [29] a he
g ain bounda ies o he aluminum ma ix (poin 4).
Due o he cooling and solidi ica ion a es o he HVOAF p ocess, he in e di usion
o Cu and Al a oms leads o he dissolu ion o Al
2
CuMg in o he aluminum ma ix [71].
As a esul , he Al
2
Cu phase was no obse ed in he new coa ed ma e ial, which ins ead
o med he Al
2
CuMg phase. This ans o ma ion has also been obse ed in p e ious s ud-
ies [72,73], pa icula ly when he alloy con ains high magnesium le els and mode a e
amoun s o coppe ollowing he homogeniza ion ea men .
Mo eo e , he p ima y polygonal and eu ec ic globula Mg
2
Si phases we e ag-
men ed and dispe sed along g ain bounda ies [73]. I is no ed ha he dissolu ion o he
Mg
2
Si phase is much mo e apid han he one o Al
2
Cu and Al
2
CuMg [74].
Addi ionally, because he HVOAF p ocess was no pe o med in a p o ec i e a mos-
phe e, some oxides we e de ec ed. Some o hese oxides we e elonga ed and pa allel o
he subs a e, po en ially esul ing in a highe ha dness in he new coa ing [75]. These
oxides could also ac as lub ican s du ing he sliding p ocess [76]. Sphe ical po es, appea -
ing as black spo s wi hin he coa ing, we e iden i ied, especially a he bo om o he coa -
ing. Using ImageJ so wa e e sion 1.54j, i was demons a ed ha he po osi y a ea was
less han 2%, which is a low alue compa ed o wha is ypically epo ed o he mal
sp ay coa ings [77]. These small po es in HVOF sp aying a e common due o sh inkage
po osi y [78]. Acco ding o he li e a u e collec ed, po osi y is a ec ed by uel low a e,
powde a e, and he sp ay dis ance [9,13,67].
As can be app ecia ed in he image, i was demons a ed ha he HVOAF p ocess
esul ed in good adhesion be ween he subs a e and he coa ing [11]. This p ocess elimi-
na es he need o pos - ea men s ypically equi ed o enhance adhesi e s eng h in
o he he mal me hods [4].
Table 4. Chemical composi ion (w .%) o new mul icomponen -based coa ed ma e ial.
Poin Al Mg Si Cu Mn Fe
1 97.14 1.0 - 1.30 0.6
2 82.8 7.9 5.5 3.6 0.4
3 78.6 8.1 5.9 6.8 0.2 0.5
4 68.9 6.5 4.8 25.4 0.4
Figu e 4. SEM mic og aphics o he new mul icomponen -based coa ing a he magni ica ion o
×1000 and ×2000.
Figu e 4. SEM mic og aphics o he new mul icomponen -based coa ing a he magni ica ion o
×1000 and ×2000.
Table 4. Chemical composi ion (w .%) o new mul icomponen -based coa ed ma e ial.
Poin Al Mg Si Cu Mn Fe
1 97.14 1.0 - 1.30 0.6
2 82.8 7.9 5.5 3.6 0.4
3 78.6 8.1 5.9 6.8 0.2 0.5
4 68.9 6.5 4.8 25.4 0.4
Due o he cooling and solidi ica ion a es o he HVOAF p ocess, he in e di usion o
Cu and Al a oms leads o he dissolu ion o Al
2
CuMg in o he aluminum ma ix [
71
]. As a
esul , he Al
2
Cu phase was no obse ed in he new coa ed ma e ial, which ins ead o med
he Al
2
CuMg phase. This ans o ma ion has also been obse ed in p e ious s udies [
72
,
73
],
pa icula ly when he alloy con ains high magnesium le els and mode a e amoun s o
coppe ollowing he homogeniza ion ea men .
Mo eo e , he p ima y polygonal and eu ec ic globula Mg
2
Si phases we e agmen ed
and dispe sed along g ain bounda ies [
73
]. I is no ed ha he dissolu ion o he Mg
2
Si
phase is much mo e apid han he one o Al2Cu and Al2CuMg [74].
Addi ionally, because he HVOAF p ocess was no pe o med in a p o ec i e a mo-
sphe e, some oxides we e de ec ed. Some o hese oxides we e elonga ed and pa allel o he
subs a e, po en ially esul ing in a highe ha dness in he new coa ing [
75
]. These oxides
could also ac as lub ican s du ing he sliding p ocess [
76
]. Sphe ical po es, appea ing
as black spo s wi hin he coa ing, we e iden i ied, especially a he bo om o he coa ing.
Using ImageJ so wa e e sion 1.54j, i was demons a ed ha he po osi y a ea was less
han 2%, which is a low alue compa ed o wha is ypically epo ed o he mal sp ay
coa ings [
77
]. These small po es in HVOF sp aying a e common due o sh inkage po os-
i y [
78
]. Acco ding o he li e a u e collec ed, po osi y is a ec ed by uel low a e, powde
a e, and he sp ay dis ance [9,13,67].
As can be app ecia ed in he image, i was demons a ed ha he HVOAF p ocess
esul ed in good adhesion be ween he subs a e and he coa ing [
11
]. This p ocess elimi-
na es he need o pos - ea men s ypically equi ed o enhance adhesi e s eng h in o he
he mal me hods [4].
By analyzing a highe magni ica ions (
×
5000) and applying an EDS line analysis
(Figu e 5)
and a complemen a y EDS mapping o elemen al analysis (Figu e 6), he in e -
ace o he new coa ing was s udied in mo e de ail. The in e ace was especially en iched
in coppe , wi h aluminum, magnesium, and silicon as seconda y elemen s, co ela ed wi h
Coa ings 2024,14, 1135 9 o 22
he p esence o he Al
2
CuMg phase. The Al
2
CuMg phase can se e as a c ack ini ia ion
sou ce [
79
]. Howe e , i s p esence is ad an ageous in aluminum alloys [
80
] due o he
highe s eng h and ha dness alues p o ided by he Al
2
CuMg phase [
81
] compa ed o he
Al
2
Cu phase. Addi ionally, he deposi ion o his in e media e laye con ibu es o be e
adhesion o he coa ing o he subs a e [25].
Coa ings 2024, 14, x FOR PEER REVIEW 9 o 23
By analyzing a highe magni ica ions (×5000) and applying an EDS line analysis (Fig-
u e 5) and a complemen a y EDS mapping o elemen al analysis (Figu e 6), he in e ace
o he new coa ing was s udied in mo e de ail. The in e ace was especially en iched in
coppe , wi h aluminum, magnesium, and silicon as seconda y elemen s, co ela ed wi h
he p esence o he Al
2
CuMg phase. The Al
2
CuMg phase can se e as a c ack ini ia ion
sou ce [79]. Howe e , i s p esence is ad an ageous in aluminum alloys [80] due o he
highe s eng h and ha dness alues p o ided by he Al
2
CuMg phase [81] compa ed o
he Al
2
Cu phase. Addi ionally, he deposi ion o his in e media e laye con ibu es o be -
e adhesion o he coa ing o he subs a e [25].
Figu e 5. Line scan EDS analysis showing he dis ibu ion o each elemen ac oss he di e en alloys
and in e aces.
Figu e 6. EDS map o elemen dis ibu ion in he alloys and in e ace.
3.2. Ha dness
Figu e 7 shows he op ical mic og aph wi h an example o inden a ions pe o med
on he subs a e, he in e ace, and he op and bo om o he coa ing, along wi h he
g aphic displaying he ob ained mean esul s and s anda d de ia ion. The ha dness ack
was smalle a he in e ace, esul ing in a ha dness o a ound 200 HV10. This co obo-
a ed he mic os uc u e analysis, which showed he Al
2
CuMg phase p ecipi a ing a he
in e ace, and his ha de Al
2
CuMg phase p o ides highe ha dness alues [81]. No ably,
no c acks we e iden i ied a he in e ace a e he inden a ions we e pe o med, ypical o
agile phases. By compa ing he ha dness o he coa ing wi h ha o he subs a e, i was
demons a ed ha he new mul icomponen Al80Mg10Si5Cu5 aluminum-based coa ed
ma e ial signi ican ly imp o ed he ha dness o he A6061 alloy, achie ing alues o 133
Figu e 5. Line scan EDS analysis showing he dis ibu ion o each elemen ac oss he di e en alloys
and in e aces.
Coa ings 2024, 14, x FOR PEER REVIEW 9 o 23
By analyzing a highe magni ica ions (×5000) and applying an EDS line analysis (Fig-
u e 5) and a complemen a y EDS mapping o elemen al analysis (Figu e 6), he in e ace
o he new coa ing was s udied in mo e de ail. The in e ace was especially en iched in
coppe , wi h aluminum, magnesium, and silicon as seconda y elemen s, co ela ed wi h
he p esence o he Al
2
CuMg phase. The Al
2
CuMg phase can se e as a c ack ini ia ion
sou ce [79]. Howe e , i s p esence is ad an ageous in aluminum alloys [80] due o he
highe s eng h and ha dness alues p o ided by he Al
2
CuMg phase [81] compa ed o
he Al
2
Cu phase. Addi ionally, he deposi ion o his in e media e laye con ibu es o be -
e adhesion o he coa ing o he subs a e [25].
Figu e 5. Line scan EDS analysis showing he dis ibu ion o each elemen ac oss he di e en alloys
and in e aces.
Figu e 6. EDS map o elemen dis ibu ion in he alloys and in e ace.
3.2. Ha dness
Figu e 7 shows he op ical mic og aph wi h an example o inden a ions pe o med
on he subs a e, he in e ace, and he op and bo om o he coa ing, along wi h he
g aphic displaying he ob ained mean esul s and s anda d de ia ion. The ha dness ack
was smalle a he in e ace, esul ing in a ha dness o a ound 200 HV10. This co obo-
a ed he mic os uc u e analysis, which showed he Al
2
CuMg phase p ecipi a ing a he
in e ace, and his ha de Al
2
CuMg phase p o ides highe ha dness alues [81]. No ably,
no c acks we e iden i ied a he in e ace a e he inden a ions we e pe o med, ypical o
agile phases. By compa ing he ha dness o he coa ing wi h ha o he subs a e, i was
demons a ed ha he new mul icomponen Al80Mg10Si5Cu5 aluminum-based coa ed
ma e ial signi ican ly imp o ed he ha dness o he A6061 alloy, achie ing alues o 133
Figu e 6. EDS map o elemen dis ibu ion in he alloys and in e ace.
3.2. Ha dness
Figu e 7shows he op ical mic og aph wi h an example o inden a ions pe o med
on he subs a e, he in e ace, and he op and bo om o he coa ing, along wi h he
g aphic displaying he ob ained mean esul s and s anda d de ia ion. The ha dness
ack was smalle a he in e ace, esul ing in a ha dness o a ound 200 HV10. This
co obo a ed he mic os uc u e analysis, which showed he Al
2
CuMg phase p ecipi a ing
a he in e ace, and his ha de Al
2
CuMg phase p o ides highe ha dness alues [
81
].
No ably, no c acks we e iden i ied a he in e ace a e he inden a ions we e pe o med,
ypical o agile phases. By compa ing he ha dness o he coa ing wi h ha o he subs a e,
i was demons a ed ha he new mul icomponen Al80Mg10Si5Cu5 aluminum-based
coa ed ma e ial signi ican ly imp o ed he ha dness o he A6061 alloy, achie ing alues o
133 HV10
±
4.5, which is wo imes highe . In addi ion, i was shown ha he new coa ing
p o ided a simila ha dness alue as he new mul icomponen Al80Mg10Si5Cu5 alloy in
i s as-cas condi ion.
Coa ings 2024,14, 1135 16 o 22
Addi ionally, he Al
2
Cu phase was no de ec ed, wi h only he p esence o he Al
2
CuMg
phase p ecipi a ed in a spla pa e n-like s uc u e, pa icula ly a he in e aces.
As shown in Figu e 12, he mo phology and coppe con en in he Mg
2
Si and Al
2
CuMg
phases inc eased wi h he cooling a e, esul ing in a supe sa u a ed coppe solu ion. I
has been demons a ed ha adding coppe inc eases he elec ical conduc i i y [
118
]. Also,
i has been p o ed ha al e ing he o m, size, and mo phology o he alloying elemen s
enhances he conduc i i y o he alloy [
119
]. As a esul , he mic os uc u al ans o ma ions
inc ease elec ical conduc i i y [120–122].
Finally, Figu e 13 co ela es cooling a es wi h he co esponding mo phology o he
main cons i uen s in Al80Mg10Si5Cu5 and i s conduc i i y alues. The esul s demon-
s a ed ha elec ical conduc i i y is s ongly in luenced by bo h he cooling a e and he
mo phology o he cons i uen s [123].
Coa ings 2024, 14, x FOR PEER REVIEW 16 o 23
Table 9. App ox. Chemical composi ion (w .%) o phases con ained in Al80Mg10Si5Cu alloy.
Phase G a i y Sand G a i y Die Cas HPDC The mal Sp ay
P ima y Mg
2
Si 32Mg, 33Al, 34Si, 1Cu 34Mg, 31Al, 34Si, 1Cu 30Mg, 42Al, 25Si, 3Cu -
Eu ec ic Mg
2
Si 27Mg, 42Al, 29Si, 1Cu 28Mg, 41Al, 30Si, 1Cu 17Mg, 67Al, 14Si, 3Cu -
Aluminum 93Al, 3Mg, 1Si, 2Cu 93Al, 4Mg, 1Si, 2Cu 88Al, 7Mg, 2Si, 3Cu 84Al, 8Mg, 6Si, 3Cu
Al
2
Cu 66Al, 34Cu 66Al, 4Mg, 1Si, 29Cu 66Al, 8Mg, 1Si, 24Cu -
Al
2
CuMg 80Al, 15Mg, 1Si, 10Cu 75Al, 12Mg, 2Si, 11Cu 76Al, 11Mg, 2Si, 12Cu 76Al, 6Mg, 4Si, 15Cu
Finally, Figu e 13 co ela es cooling a es wi h he co esponding mo phology o he
main cons i uen s in Al80Mg10Si5Cu5 and i s conduc i i y alues. The esul s demon-
s a ed ha elec ical conduc i i y is s ongly in luenced by bo h he cooling a e and he
mo phology o he cons i uen s [123].
Figu e 13. Co ela ion o %IACS wi h solu ion componen s and cooling a es.
4. Discussion
I has been demons a ed ha using new mul icomponen Al80Mg10Si5Cu5 alumi-
num alloys as a coa ing ma e ial o aluminum alloys imp o es mechanical, elec ical, and
ibological p ope ies. Addi ionally, he e was a sligh imp o emen in co osion e-
sis ance. The newly designed HVOAF p ocess p o ided a high-quali y coa ing wi h a
hickness o up o 130 µm, hough some po es we e p esen a he bo om o he coa ing,
accoun ing o less han 2% o he a ea. These po es a e cha ac e is ic o his p ocess. This
he mal p ocess equi es expe ienced handling and op imiza ion o pa ame e s o achie e
consis en coa ing quali y. Pa ame e s such as oxygen low a e, sp ay dis ance, and pow-
de eed a e can be op imized o imp o e po osi y and coa ing hickness.
Mic os uc u e and chemical analysis esul s indica ed good adhesion be ween he
subs a e and he coa ing. The high solidi ica ion a es led o ewe phases and a ine
mic os uc u e, esul ing in he disappea ance o he Al
2
Cu phase and he p ecipi a ion o
Mg
2
Si h oughou he ma ix. In he in e ace a ea, a high p esence o elemen al coppe
p ecipi a ed as he Al
2
CuMg phase, p o iding high ha dness wi hou c acking.
Ha dness esul s demons a ed a 50% inc ease in he new mul icomponen -based
coa ed ma e ial compa ed o he A6061 subs a e alloy, eaching alues up o 220 HV.
Figu e 13. Co ela ion o %IACS wi h solu ion componen s and cooling a es.
4. Discussion
I has been demons a ed ha using new mul icomponen Al80Mg10Si5Cu5 aluminum
alloys as a coa ing ma e ial o aluminum alloys imp o es mechanical, elec ical, and
ibological p ope ies. Addi ionally, he e was a sligh imp o emen in co osion esis ance.
The newly designed HVOAF p ocess p o ided a high-quali y coa ing wi h a hickness o
up o 130
µ
m, hough some po es we e p esen a he bo om o he coa ing, accoun ing o
less han 2% o he a ea. These po es a e cha ac e is ic o his p ocess. This he mal p ocess
equi es expe ienced handling and op imiza ion o pa ame e s o achie e consis en coa ing
quali y. Pa ame e s such as oxygen low a e, sp ay dis ance, and powde eed a e can be
op imized o imp o e po osi y and coa ing hickness.
Mic os uc u e and chemical analysis esul s indica ed good adhesion be ween he
subs a e and he coa ing. The high solidi ica ion a es led o ewe phases and a ine
mic os uc u e, esul ing in he disappea ance o he Al
2
Cu phase and he p ecipi a ion o
Mg
2
Si h oughou he ma ix. In he in e ace a ea, a high p esence o elemen al coppe
p ecipi a ed as he Al2CuMg phase, p o iding high ha dness wi hou c acking.
Ha dness esul s demons a ed a 50% inc ease in he new mul icomponen -based
coa ed ma e ial compa ed o he A6061 subs a e alloy, eaching alues up o 220 HV.
T ibological p ope y esul s showed ha he ic ion coe icien dec eased by mo e
han 20% in he new mul icomponen alloy-based coa ed ma e ial compa ed o he A6061
Coa ings 2024,14, 1135 17 o 22
subs a e alloy, achie ing a s eady-s a e ic ion coe icien alue o 0.40. This alue was
simila o ha obse ed o he new mul icomponen alloy in i s as-cas s a e. Addi ionally,
he wea coe icien dec eased also signi ican ly, being app oxima ely 2.5 imes lowe han
ha o he uncoa ed sample.
The wea a e coe icien and he examina ion o he mic os uc u e o he wea ack
su ace and c oss-sec ional su ace in he new coa ed ma e ial indica ed mild wea condi-
ions, cha ac e ized by ab asion as he p incipal wea mechanism. In con as , he subs a e
wi hou he coa ing exhibi ed mode a e o se e e wea , showing delamina ed a eas along-
side ploughed a eas a ibu ed o a combina ion o ab asion and
delamina ion mechanisms.
Compa ing he ha dness alues o he expe imen al alloys e ealed ha samples wi h
highe ha dness demons a ed a lowe COF du ing he sliding p ocess. Addi ionally, i
was obse ed ha samples wi h signi ican ly highe alues o he coe icien o ic ion
co esponded o he highes wea a e. Howe e , i was no ed ha samples wi h a simila
COF did no necessa ily exhibi a linea ela ion wi h he wea a e.
The elec ical conduc i i y esul s showed a signi ican inc ease (
×
3 imes) compa ed
o he mul icomponen alloy in an as-cas s a e. The conduc i i y alues app oached hose
o he A6061 subs a e and we e compa able o a pu e aluminum alloy. The analysis
demons a ed a s ong in luence o he cooling a e and mo phology o he cons i uen s on
elec ical conduc i i y.
Co osion esis ance esul s demons a ed ha he mul icomponen alloy had highe
alues compa ed wi h o he con en ional and mul icomponen aluminum alloys and we e
also highe han hose o he hea - ea ed A6061 alloy. Howe e , hey we e highe han
he alues o A6061 alloy in i s as-cas s a e. Pa ame e s such as p ehea ing and angle
o incidence should be in es iga ed o a u he inc ease in he co osion esis ance o
he coa ing.
5. Conclusions
This s udy has explo ed he ad anced p ope ies o mul icomponen alloys, cla i ied
wea mechanisms, and showcased he bene i s o a new he mal sp ay sys em o high-
quali y coa ings.
A new coa ed ma e ial based on a new mul icomponen aluminum alloy has been
de eloped, ea u ing enhanced mechanical, elec ical, and ibological p ope ies.
Fu u e wo k will ocus on op imizing some he mal sp ay pa ame e s o enhance
speci ic p ope ies. To achie e hicke coa ings, a highe powde eeding a e will be in es-
iga ed. Addi ionally, he angle o incidence and p ehea ing will be op imized, as a lowe
angle o incidence and highe p ehea ing ha e been shown o imp o e
co osion esis ance.
Fu he mo e, he applica ion o he Al80Mg10Si5Cu5 mul icomponen alloy on he
o he ypes o aluminum subs a es will be in es iga ed. Ex uded aluminum pa s such
as A5754 o A6060 and cas ing aluminum pa s such as AlSi9Cu3 could bene i om
inc eased elec ical conduc i i y and imp o ed wea p ope ies. This p esen s a signi ican
oppo uni y o he au omo i e indus y, especially in de eloping elec ic ehicles and
hei ba e ies. I could lead o inc eased speed and g ea e load-bea ing capaci y.
Finally, s udies a e an icipa ed o e alua e hese high-pe o mance p ope ies unde
eal condi ions and in cas ing pa s, as well as he beha io agains hyd ogen agiliza ion.
Au ho Con ibu ions: Concep ualiza ion: E.V. and I.V.; me hodology: C.V. and J.A.; alida ion:
E.V., I.V., J.A., M.T.G., N.B., and I.H.; in es iga ion: E.V., I.V., and J.A.; w i ing—o iginal d a
p epa a ion: E.V., I.V., and J.A.; e iew and edi ing: M.T.G. and N.B.; supe ision: I.V. and J.A.; p ojec
adminis a ion: E.V. and I.V.; unding acquisi ion: I.V. and J.A. All au ho s ha e ead and ag eed o
he published e sion o he manusc ip .
Funding: This wo k has been pa ially unded by he Basque Go e nmen h ough he ELKARTEK
KK-2020_00047 (CEMAP), KK-2022_00082 (MINERVA), and KK-2023/00020 (DESGAS).
Ins i u ional Re iew Boa d S a emen : No applicable.
In o med Consen S a emen : No applicable.
Coa ings 2024,14, 1135 18 o 22
Da a A ailabili y S a emen : Da a is con ained wi hin he a icle.
Con lic s o In e es : The au ho s decla e no con lic s o in e es .
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