In this study, three kinds of A380/Al₂O₃ composite coatings were prepared by cold spray (CS) using spherical, irregular and spherical + irregular shaped Al₂O₃ particulates separately mixed in the original A380 alloy powders. The influence of Al₂O₃ particulates’ morphology on the microstructural characteristics (i.e. retention of Al₂O₃ content in coatings, coating/matrix interfacial bonding, pore size distribution and morphology etc.) and wear performance of the coatings was investigated by scanning electron microscopy (SEM), X-ray computed tomography (XCT) and 3-D optical profilometry. Results indicated that the spherical Al₂O₃ shows obvious tamping effect during deposition process. As a result, the interface showed a wavy shape while the matrix and particulates were mechanical interlocked with much improved adhesion. In addition, the porosity of the coating was minimized and the pores exhibited curved spherical structure with reduced dimensions. The irregular Al₂O₃ particles predominantly displayed the embedding effect together with fragmentation of Al₂O₃ particulates. Consequently, poor coating/ matrix interfacial bonding, high porosity and the formation of angular-shaped pores were resulted in the coating. Dry sliding wear tests results revealed that the wear resistance of the coating is directly related with the retained content of Al₂O₃ in the coating. The coating containing irregular Al₂O₃ particulates displayed superior wear performance with its wear rate one seventh of that of the pure A380 alloy coating. The coating containing both kinds of Al₂O₃ particulates showed mixed characteristics of above two kinds of Al₂O₃ composite coatings.

在这项研究中，通过冷喷涂（CS）使用分别混合在原始A380合金粉末中的球形，不规则形状和球形+不规则形状的Al ₂ O ₃颗粒，通过冷喷涂（CS）制备了三种A380 / Al ₂ O ₃复合涂层。通过扫描研究了Al ₂ O ₃颗粒形态对显微组织特征（即涂层中Al ₂ O _3的保留率，涂层/基体界面结合，孔径分布和形态等）和涂层磨损性能的影响。电子显微镜（SEM），X射线计算机断层扫描（XCT）和3-D光学轮廓仪。结果表明球形Al₂ O ₃在沉积过程中显示出明显的夯实效果。结果，界面呈波浪形，而基体和颗粒机械互锁，附着力大大提高。另外，涂层的孔隙率被最小化并且孔表现出尺寸减小的弯曲球形结构。不规则的Al ₂ O ₃颗粒主要表现出嵌入效果以及Al ₂ O _3的碎裂微粒。结果，导致涂层中差的涂层/基体界面结合，高孔隙率和形成角形孔。干滑动磨损测试结果表明，涂​​层的耐磨性与涂层中Al ₂ O ₃的保留含量直接相关。含有不规则Al ₂ O ₃颗粒的涂层具有优异的磨损性能，其磨损率是纯A380合金涂层的七分之一。包含两种Al ₂ O ₃颗粒的涂层表现出上述两种Al ₂ O ₃复合涂层的混合特性。