Microstructure of high velocity oxy-fuel sprayed Ti₂AlC coatings

The microstructure formation and phase transformations in Ti₂AlC-rich coatings deposited by High Velocity Oxy-fuel spraying of Maxthal 211^® powders is presented. High resolution electron microscopy analysis, using both scanning and transmission electron microscopy with energy dispersive spectrometry and energy filtering, combined with X-ray diffraction reveals that the coatings consist of Ti₂AlC grains surrounded by regions of very small TiC grains embedded in Ti _x Al _y . The composition of the Ti _x Al _y depends on its surrounding and varies with size and distribution of the adjacent TiC grains. Impact of spray parameters on coating microstructure is also discussed. Two spray parameters were varied; powder size distribution and flame power. They were found to greatly affect the coating microstructure. Increasing powder size and decreasing flame power increase the amount of Ti₂AlC, but produces thinner coatings with lower cohesion. Larger powder size will also decrease oxygen incorporation.