Combinatorial synthesis of AlNi alloys by low-pressure cold spray deposition and post-laser alloying process

Aluminum-Nickel (Al Ni) alloys are of great interest due to their exceptional high-temperature wear and corrosion resistance, making them valuable in transport, energy, and materials processing applications. However, challenges in the production and shaping of these alloys, particularly as thick coatings, remain significant. This study introduces an innovative method for the high-throughput synthesis of Al Ni coatings, utilizing a two-step process: low-pressure cold spray deposition followed by laser surface alloying. The combination of these two techniques not only improves the synthesis process but also opens avenues for exploring new material compositions with specific application requirements. This approach holds significant potential for accelerating the development and optimization of advanced coatings and multiphase compounds in applications such as repair and additive manufacturing. Aluminum and nickel powders were co-sprayed to create coatings with controlled compositions ranging from 50Al 50Ni to 10Al 90Ni (wt%). Subsequent laser treatment induced in-situ alloying and homogenization, resulting in dense, uniform Al Ni coatings. The microstructure and chemical composition were characterized using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS), while X-ray Diffraction (XRD) identified the formation of various phases, including Al 3 Ni and AlNi 3 phases. The process demonstrated effective alloying and microstructural homogeneity, with residual alumina present at the surface. Despite the presence of some microstructural defects, such as cracking, this method provides a robust foundation for further refinement and opens new possibilities for tailoring alloy properties through combinatorial cold spray and laser alloying techniques. • Combinatorial deposition of Aluminum-Nickel mixtures by low-pressure cold spray • Surface laser alloying of Aluminum-Nickel cold spray coatings • XRD identification of Aluminum-Nickel intermetallic phases • Micro-Hardness of Al Ni intermetallics from 10 to 50 wt% Al