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<p>Aerosol deposition (AD) is a kinetic spray process capable of depositing ceramic coatings at room temperature, but AD process development is generally a laborious exploration of a large process parameter space. This paper presents a case study investigating whether laser-induced particle impact testing (LIPIT) could be applied to expedite development of an alumina (Al<sub>2</sub>O<sub>3</sub>) coating on nickel (Ni): Specifically, whether LIPIT measurements could predict critical velocities of adhesion on Ni and Al<sub>2</sub>O<sub>3</sub>, and the effect of ball milling the Al<sub>2</sub>O<sub>3</sub> powder. Because LIPIT has a diffraction-limited lower bound on imageable particle size, the usefulness of Al<sub>2</sub>O<sub>3</sub> powder agglomerates as a proxy for single particles was additionally studied. Overall, LIPIT measurements and AD sprays agreed that ball milling dramatically improves adhesion. Additionally, LIPIT measurements of critical velocity of adhesion of Al<sub>2</sub>O<sub>3</sub> powder agglomerates on Ni and Al<sub>2</sub>O<sub>3</sub> substrates (150 meters per second [m/s] and 250 m/s, respectively) quantitatively agreed with predictions from a previously published model based on picoindentation and molecular dynamics simulations. Together, these findings support the established hypothesis that Al<sub>2</sub>O<sub>3</sub> adheres via a dislocation-mediated mechanism in AD, that Al<sub>2</sub>O<sub>3</sub> powder agglomerates adhere as individual constituent particles rather than collectively, and that, for this case study, LIPIT measurements were predictive of AD process parameters.</p>

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Support of Adhesion Mechanisms in Al2O3 Aerosol Deposition Through Laser-Induced Particle Impact Testing

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • Shannon E. Murray,
  • Alex Sarracino,
  • Shane L. McPherson,
  • Ping Lu,
  • Michael J. Abere,
  • Thomas J. Hardin

摘要

Aerosol deposition (AD) is a kinetic spray process capable of depositing ceramic coatings at room temperature, but AD process development is generally a laborious exploration of a large process parameter space. This paper presents a case study investigating whether laser-induced particle impact testing (LIPIT) could be applied to expedite development of an alumina (Al2O3) coating on nickel (Ni): Specifically, whether LIPIT measurements could predict critical velocities of adhesion on Ni and Al2O3, and the effect of ball milling the Al2O3 powder. Because LIPIT has a diffraction-limited lower bound on imageable particle size, the usefulness of Al2O3 powder agglomerates as a proxy for single particles was additionally studied. Overall, LIPIT measurements and AD sprays agreed that ball milling dramatically improves adhesion. Additionally, LIPIT measurements of critical velocity of adhesion of Al2O3 powder agglomerates on Ni and Al2O3 substrates (150 meters per second [m/s] and 250 m/s, respectively) quantitatively agreed with predictions from a previously published model based on picoindentation and molecular dynamics simulations. Together, these findings support the established hypothesis that Al2O3 adheres via a dislocation-mediated mechanism in AD, that Al2O3 powder agglomerates adhere as individual constituent particles rather than collectively, and that, for this case study, LIPIT measurements were predictive of AD process parameters.