| Abstract Scope |
Cold spray deposition of metal matrix composites (MMCs) with high ceramic particulate content remains a significant challenge due to the limited plastic deformability of hard SiC particles, which promotes particle rebound, reducing deposition efficiency. To address this, in situ heat treatment via laser-assisted cold spray (LACS) was employed to deposit Al/SiC MMCs with SiC exceeding 40 vol.%, higher than that achievable by conventional cold spray. To enhance metallic bonding in the as-sprayed coating, high-temperature annealing was subsequently applied. Microstructures were characterized using SEM, EBSD, and TEM, while micro- and nano-indentation were used to evaluate mechanical properties. Results show that while LACS promotes ceramic retention and improves interparticle contact, unbonded regions persist at Al/Al and Al/SiC interfaces in the as-sprayed condition, acting as stress concentrators, degrading mechanical performance. Annealing was found to mitigate these deficiencies by driving thermally activated interparticle diffusion bonding, promoting recrystallization, and relieving residual stresses. |