Powder Treatment for Increased Thickness of Iron Coatings Produced by the Powder Aerosol Deposition Method and Formation
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Powder Treatment for Increased Thickness of Iron Coatings Produced by the Powder Aerosol Deposition Method and Formation of Iron–Alumina Multilayer Structures Nico Leupold1 • Stefan Denneler2 • Gotthard Rieger2 • Ralf Moos1
Submitted: 9 April 2020 / in revised form: 23 July 2020 / Accepted: 14 September 2020 Ó The Author(s) 2020
Abstract The powder aerosol deposition (PAD) method is a well-known process to fabricate dense layers at room temperature directly from the powder. It is particularly suitable for the deposition of ceramic materials. Compared to these, the use of metal powders (here iron), which are significantly more ductile and have a higher density than typical ceramic powders, has not yet been investigated in detail for PAD. In the first step of this work, the iron powder is characterized by scanning electron microscopy and x-ray diffraction. In order to improve the deposition behavior, the influence of heat treatment on the crystallite and the particle size of the iron powder is investigated. It is shown that the crystallite size of iron powders is reduced down to a nanocrystalline size during deposition. The magnetic properties of the iron powder as well as the layers are investigated by means of coercive field development. Although the initial coercivity raises after deposition, potential applications for flux guiding in microelectronic sensors and devices are feasible. In the second step, thin metal layers (iron) and ceramics (aluminum oxide) are
This article is part of a special topical focus in the Journal of Thermal Spray Technology on Aerosol Deposition and Kinetic Spray Processes. This issue was organized by Dr. Kentaro Shinoda, National Institute of Advanced Industrial Science and Technology (AIST); Dr. Frank Gaertner, Helmut-Schmidt University; Prof. Changhee Lee, Hanyang University; Prof. Ali Dolatabadi, Concordia University; and Dr. Scooter Johnson, Naval Research Laboratory. & Ralf Moos [email protected] 1
Department of Functional Materials, University of Bayreuth, 95440 Bayreuth, Germany
2
Siemens AG, Corporate Technology, 81739 Munich, Germany
deposited alternatingly to produce iron–alumina multilayer structures. Keywords aerosol deposition method (ADM) crystallite size magnetic coercivity metal deposition microstrain room temperature impact consolidation (RTIC) vacuum kinetic spraying (VKS)
Introduction The powder aerosol deposition (PAD) method (or only aerosol deposition method, ADM (Ref 1)) is an intensively studied method to produce dense ceramic layers directly from the powder at room temperature. In short, in the PAD process, the powders are converted into an aerosol with the help of a carrier gas flow and fed into the deposition chamber via a nozzle. The deposition chamber is evacuated to a few mbar by means of a pump, which accelerates the aerosol to several hundred meters per second due to the pressure difference. When the particles hit the substrate in the deposition chamber at high speed, they break up and form the nanocry
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