Composite Coatings from Layered Precursors: Material Structure Modeling and Thermal Control

摘要

This research introduces and analyzes new technologies for deposition of metal-matrix composite (MMC) coatings. The coating methods use novel custom precursor materials, made of the matrix metal in sheets and the reinforcing phase in powder or fiber form, rolled or twisted in a layered sandwich sheet or particulate-cored wire. Aluminum or nickel aluminide matrix is used in combination with alumina and/or silicon carbide reinforcement materials. The precursors are fused on the substrate by a robotically scanned laser-beam or plasma-arc welding source, under infrared thermal monitoring and feedback regulating the heat and mass deposition variables. Thus, the desired coating structure is obtained by real-time, adaptive control of the temperature distribution to reference thermal conditions, obtained experimentally and coded in a material database.