Application of high current pulsed electron beam irradiation to smoothing of cold spray aluminum bronze coating

The aim of the work was investigation of the effect of high current pulsed electron beam irradiation (HCPEBI) with the energy density Es = 18 J/cm2, 20 pulses on the surface roughness, microstructure, phase composition and microhardness of the near-surface layer of aluminum bronze coating deposited on aluminum alloy using cold spray. Using SEM, line and 3D profilometry it was shown that HCPEBI in the used regime enabled smoothing of relief roughness of ∼50 μm in height. The content of free volume in the layer essentially decreased: there was very low number of small pores instead of big voids and delamination along the particles interfaces. Using XRD and TEM, formation of the ordered β1’ martensite of Cu3Al compound after HCPEBI was revealed. The microhardness of the layer decreased from 5.1 down to 2.2 GPa due to disappearance of the deformation-induced defects and phase transformation. •Cold spray bronze coating was processed with HCPEBI for the first time.•Continuous porous-free surface is formed after HCPEBI with highest energy density.•α → β1’ phase transition occurs due to superfast heating/cooling during HCPEBI•Hμ decreases after HCPEBI due to recovery of defect structure and phase transition.