About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Nanocomposite Materials: Innovations in Design, Fabrication, and Applications
|
| Presentation Title |
Cold-Sprayed Dual-Matrix Al-CNT Nanocomposite Coatings for Enhanced Corrosion Resistance and Mechanical Performance |
| Author(s) |
Sherry Morad, Matthew Wadge, Tanvir Hussain, Amal Esawi |
| On-Site Speaker (Planned) |
Sherry Morad |
| Abstract Scope |
Corrosion costs billions annually, besides operational and environmental challenges. This work introduces a novel cold sprayed dual-matrix (DM) aluminum-carbon nanotube (Al-CNT) nanocomposite coating. This design balances particle ductility with CNT reinforcement to enhance deposition. Feedstock powders were synthesized via HEBM using minimized milling time to improve process cost efficiency, then cold sprayed at CNT contents of 0.5, 1, and 2 wt.%. CNT incorporation enhanced particle deformation and inter-splat bonding, reducing porosity and surface roughness versus pure Al coatings. The 1 wt.% DM coating showed the most compact microstructure and lowest corrosion rate, representing approximately 80% and 60% reduction versus steel substrate and pure Al coating respectively. In contrast, 2 wt.% DM achieved higher nanohardness and wear performance but suffered over-deformation, coating heterogeneity and higher corrosion rates. Results show that moderate CNT content (up to 1%) in dual-matrix design provides the best balance between coating integrity, corrosion resistance and mechanical performance. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Composites, Nanotechnology, Surface Modification and Coatings |