A bulk-type Ta material is fabricated using the kinetic spray process and its microstructure and physical properties are investigated. Ta powder with an angular size in the range 9-37 μm (purity 99.95%) is sprayed on a Cu plate to form a coating layer. As a result, ~7 mm-sized bulk-type high-density material capable of being used as a sputter material is fabricated. In order to assess the physical properties of the thick coating layer at different locations, the coating material is observed at three different locations (surface, center, and interface). Furthermore, a vacuum heat treatment is applied to the coating material to reduce the variation of physical properties at different locations of the coating material and improve the density. OM, Vickers hardness test, SEM, XRD, and EBSD are implemented for analyzing the microstructure and physical properties. The fabricated Ta coating material produces porosity of 0.11~0.12%, hardness of 311~327 Hv, and minor variations at different locations. In addition, a decrease in the porosity and hardness is observed at different locations upon heat treatment.

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• Sintering Behavior and Microstructures of Tantalum and Tantalum-Tungsten Alloys Powders
  Youngmoo Kim, Sung Ho Yang, Seong Lee, Sung Ho Lee, Joon-Woong Noh
  Journal of Korean Powder Metallurgy Institute.2020; 27(5): 373.     CrossRef
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  Gi-Su Ham, Dong-Yeol Wi, Jun-Mo Yang, Kee-Ahn Lee
  Journal of Thermal Spray Technology.2019; 28(8): 1974.     CrossRef
• Mechanical properties of Mo-Nb-Si-B quaternary alloy fabricated by powder metallurgical method
  Jong Min Byun, Su-Ryong Bang, Se Hoon Kim, Won June Choi, Young Do Kim
  International Journal of Refractory Metals and Hard Materials.2017; 65: 14.     CrossRef

This study manufactured a CIG-based composite coating layer utilizing a new warm spray process, and a mixed powder of Cu-20at.%Ga and Cu-20at.%In. In order to obtain the mixed powder with desired composition, the Cu-20at.%Ga and Cu-20at.%In powders were mixed with a 7:1 ratio. The mixed powder had an average particle size of 35.4 μm. Through the utilization of a warm spray process, a CIG-based composite coating layer of 180 μm thickness could be manufactured on a pure Al matrix. To analyze the microstructure and phase, the warm sprayed coating layer underwent XRD, SEM/EDS and EMPA analyses. In addition, to improve the physical properties of the coating layer, an annealing heat treatment was conducted at temperatures of 200°C, 400°C and 600°C for 1 hour each. The microstructure analysis identified α-Cu, Cu₄In and Cu₃Ga phases in the early mixed powder, while Cu₄In disappeared, and additional Cu₉In₄ and Cu₉Ga₄ phases were identified in the warm sprayed coating layer. Porosity after annealing heat treatment reduced from 0.75% (warm sprayed coating layer) to 0.6% (after 600°C/1 hr. heat treatment), and hardness reduced from 288 Hv to 190 Hv. No significant phase changes were found after annealing heat treatment.

Citations

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• Fabrication and Microstructure/Properties of Bulk-typeTantalum Material by a Kinetic Spray Process
  Ji-Hye Lee, Ji-Won Kim, Kee-Ahn Lee
  Journal of Korean Powder Metallurgy Institute.2016; 23(1): 8.     CrossRef
• Effect of Heat Treatment Environment on the Microstructure and Properties of Kinetic Sprayed Tantalum Coating Layer
  Ji-Hye Lee, Hyung-Jun Kim, Kee-Ahn Lee
  Journal of Korean Powder Metallurgy Institute.2015; 22(1): 32.     CrossRef