Intermetallic Phase Evolution of Cold-Sprayed Ni-Ti Composite Coatings: Influence of As-Sprayed Chemical Composition

Owing to low-temperature deposition conditions and high deposition rate, cold spray offers unique advantages in manufacturing a wide variety of metallic and composite coatings including metal matrix composites produced from physically blended powders. One of the challenges of producing composite coatings using cold spray is the deviation of coatings composition from the blended feedstock powder composition. This is of utmost importance as it affects the composition and phase evolution of intermetallic forming coatings during post spray heat treatment. In this work, cold spray of composite NiTi coatings and formation of intermetallics from post spray heat treatment were investigated as a first step to examine the potential of producing equiatomic bulk NiTi by cold spray. Three different physically blended Ni and Ti powders mixtures were sprayed on titanium substrates to address the coating composition variation from the blended feedstock powder and study its influence on phase evolution during post spray heat treatment. High-density and well-dispersed composite coatings were achieved for each case. EDS analysis revealed as-sprayed coatings with 10.5, 35.9 and 56.9 at.% Ni (and with balanced Ti ratios) from the three powder mixtures. Annealing treatments were conducted at 400, 500 and 900 °C for 1 and 2 h and comparative studies of the intermetallic compound formations were carried out. Microstructural investigation showed that all three equilibrium intermetallics phases of binary NiTi phase diagram (Ni₃Ti, Ti₂Ni and NiTi) formed in the two Ni-rich composite coatings with NiTi phase being maximum in the coating with the closest composition to equiatomic ratio while only Ti₂Ni phase formed in the Ti-rich coating after annealing. Thermal etching analysis of coatings showed that NiTi phase forms with a gradient microstructure from Ti splats boundary toward the center of splats, which is attributed to the grain refinement of CS samples at splat boundary and intermetallic nucleation mechanism.