Exploring thermal-plasma spraying technology for advanced aluminum-based materials

The plasma system was applied on two different powder system suspensions of Al-Ni and Al-Mo to synthesize different phases using a combinatorial approach. Effects of different process variables such as power level, reactor pressure, powder suspension characteristics, etc. on the characteristics of each set of powders formed separately from the mentioned suspended powder mixtures were investigated. Irrespective of the applied powder suspension system, the obtained powders contained large spherical particles that were surrounded by a cloud of fine porous particles. Different phases such as Al, Mo, Al5Mo, Mo2C, Al4C3 and AlOx were detected in the particles of the Al-Mo powder system and Al, Ni, Al4C3, AlNi, AlOx and Al3Ni in those of the Al-Ni powder system. The reasons for the formation of carbides and oxides were investigated and attributed to the air leaks that occurred during the process of solidification and/or the presence of an oxygen-laden liquid in the suspensions. [Display omitted] •Developed different Al-based materials by a combinatorial plasma approach.•Studied different parameters affecting the properties of powder suspension droplets.•Separately plasma processed Al-Mo and Al-Ni suspended powder mixtures.•Studied each set of powder particles formed from these suspended powder mixtures.