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Influence of Hot Isostatic Pressing on the Microstructure and Mechanical Properties of a Spray-Formed Al-4.5 wt.% Cu Alloy

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Abstract

Al-4.5 wt.% Cu alloy was spray atomized and deposited at varied spray heights ranging from 300 to 390 mm. The average grain sizes decreased from ~ 29 to ~ 18 μm and a concomitant increase in the hardness and the 0.2% yield strength (YS) with increase in the spray height. The respective hardness values of SF-300, SF-340, and SF-390 are 451 ± 59, 530 ± 39, and 726 ± 39 MPa and the YS are 108 ± 7, 115 ± 8, and 159 ± 10 MPa. The transmission electron micrographs revealed the morphological changes of the Al2Cu phase from irregular shaped to small plate-shaped and then subsequently to spheroidal shape due to high undercooling encountered during spray atomization with increase in spray height from 300 to 390 mm. The porosity of the spray formed deposits varied between 5 to 12%. Hot isostatic pressing of spray deposits reduced the porosity to less than 0.5% without any appreciable increase in grain size. A dislocation creep mechanism seems to be operative during the secondary processing. A comparison between as-spray formed and hot isostatically pressed deposits exemplifies improvement in mechanical properties as a result of elimination of porosity without affecting the fine grain sizes achieved during the spray-forming process.

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Acknowledgements

The authors would like to thank Mr. Raghukiran N. and Mr. Sujith R. for their technical support. Mr. Subramanyam S. V. and Mr. Dhanapalan P. are thankfully acknowledged for their technical support. Also, sincere thanks are extended to Ms. D. Kanchanamala and Mrs. S. Veerabathiran for their assistance in conducting TEM.

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Authors and Affiliations

  1. Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras, Chennai, 600036, India

    S. Devaraj, S. Sankaran & R. Kumar

  2. Defence Metallurgical Research Laboratory, Hyderabad, 500058, India

    G. Appa Rao

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  1. S. Devaraj
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  2. S. Sankaran
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  3. R. Kumar
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Correspondence to R. Kumar.

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Devaraj, S., Sankaran, S., Kumar, R. et al. Influence of Hot Isostatic Pressing on the Microstructure and Mechanical Properties of a Spray-Formed Al-4.5 wt.% Cu Alloy. J. of Materi Eng and Perform 23, 1440–1450 (2014). https://doi.org/10.1007/s11665-014-0869-z

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  • DOI: https://doi.org/10.1007/s11665-014-0869-z

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