Skip to main content Accessibility help

The study of preparation process of spray formed 7075/Al–Si bimetallic gradient composite plate

  • Lei Yu (a1), Fuyang Cao (a1), Liguo Hou (a1), Yandong Jia (a2), Hongxian Shen (a1), Haichao Li (a1), Zhiliang Ning (a1), Dawei Xing (a1) and Jianfei Sun (a1)...


To determine the spray forming process parameters of 7075/Al–Si bimetallic gradient composite plate with two gas atomizers, a calculation model of the plate has been established by using the finite element software ANSYS. The effects of different motion trajectory, advance speed, swing cycle and spray center distance on shape, and silicon distribution of deposited plate have been simulated by the APDL programming language. The results show that a smooth and uniform surface is obtained when motion trajectory is in a regular jaggies mode. The deposited plate varies from platform to stepped shape with a center distance increasing from 20 mm to 50 mm; meanwhile, the width of the transition zone decreases gradually. As the period increases to 8 s, the silicon distribution of each layer presents a jagged fluctuation. Both the thickness of the deposited plate and the width of the transition zone decrease as the advance speed increases, except the silicon distribution. Finally, the modeling and simulation of the co-spray formed 7075/Al–Si bimetallic gradient composite plate are validated by experimental investigations and the simulation results are in good agreement with the actual results.


Corresponding author

a) Address all correspondence to this author. e-mail:


Hide All

Contributing Editor: Jürgen Eckert



Hide All
1. Lee, S.W., Yeh, J.W., and Liao, Y.S.: Premium 7075 aluminium alloys produced by reciprocating extrusion. Adv. Eng. Mater. 6, 936943 (2004).
2. Liu, D., Atkinson, H.V., Kapranos, P., Jirattiticharoean, W., and Jones, H.: Microstructural evolution and tensile mechanical properties of thixoformed high performance aluminium alloys. Mater. Sci. Eng., A 361, 213224 (2003).
3. Miller, W.S., Zhuang, L., Bottema, J., Wittebrood, A.J., Smet, P.D., Haszler, A., and Vieregge, A.: Recent development in aluminium alloys for the automotive industry. Mater. Sci. Eng., A 280, 3749 (2000).
4. Andreatta, F., Terryn, H., and de Wit, J.H.W.: Corrosion behaviour of different tempers of AA7075 aluminium alloy. Electrochim. Acta 49, 28512862 (2004).
5. Deuis, R.L., Subramanian, C., and Yellup, J.M.: Dry sliding wear of aluminium composites—A review. Compos. Sci. Technol. 57, 415435 (1997).
6. Sabatini, G., Ceschini, L., Martini, C., Williams, J.A., and Hutchings, I.M.: Improving sliding and abrasive wear behaviour of cast A356 and wrought AA7075 aluminium alloys by plasma electrolytic oxidation. Mater. Des. 31, 816828 (2010).
7. Alshmri, F., Atkinson, H.V., Hainsworth, S.V., Haidon, C., and Lawes, S.D.A.: Dry sliding wear of aluminium-high silicon hypereutectic alloys. Wear 313, 106116 (2014).
8. Dwivedi, D.K.: Wear behaviour of cast hypereutectic aluminium silicon alloys. Mater. Des. 27, 610616 (2006).
9. Haque, M.M. and Sharif, A.: Study on wear properties of aluminium–silicon piston alloy. J. Mater. Process. Technol. 118, 6973 (2001).
10. Raghukiran, N. and Kumar, R.: Processing and dry sliding wear performance of spray deposited hyper-eutectic aluminum–silicon alloys. J. Mater. Process. Technol. 213, 401410 (2013).
11. Mahamood, R.M., Akinlabi, E.T., Shukla, M., and Pityana, S.: Functionally graded material: An overview. In Proceedings of the World Congress on Engineering, Vol. 3 (Newswood Limited, Hong Kong, 2012); p. 1593.
12. Muller, P., Mognol, P., and Hascoet, J-Y.: Modeling and control of a direct laser powder deposition process for functionally graded materials (FGM) parts manufacturing. J. Mater. Process. Technol. 213, 685692 (2013).
13. Cui, C., Schulz, A., Schimanski, K., and Zoch, H.W.: Spray forming of hypereutectic Al–Si alloys. J. Mater. Process. Technol. 209, 52205228 (2009).
14. Grant, P.S.: Spray forming. Prog. Mater. Sci. 39, 497545 (1995).
15. Hogg, S.C., Lambourne, A., Ogilvy, A., and Grant, P.S.: Microstructural characterisation of spray formed Si–30Al for thermal management applications. Scr. Mater. 55, 111114 (2006).
16. Jia, Y., Cao, F., Scudino, S., Ma, P., Li, H., Yu, L., Eckert, J., and Sun, J.: Microstructure and thermal expansion behavior of spray-deposited Al–50Si. Mater. Des. 57, 585591 (2014).
17. Mesquita, R.A. and Barbosa, C.A.: Spray forming high speed steel—Properties and processing. Mater. Sci. Eng., A 383, 8795 (2004).
18. Srivastava, V.C., Mandal, R.K., and Ojha, S.N.: Microstructure and mechanical properties of Al–Si alloys produced by spray forming process. Mater. Sci. Eng., A 304, 555558 (2001).
19. Wang, R. and Fichthom, K.A.: Computer simulation of metal thin-film epitaxy. Thin Solid Films 272, 223228 (1996).
20. Khor, K.A., Dong, Z.L., and Gu, Y.W.: Influence of oxide mixtures on mechanical properties of plasma sprayed functionally graded coating. Thin Solid Films 368, 8692 (2000).
21. Kang, S. and Chang, D.H.: Modelling of billet shapes in spray forming using a scanning atomizer. Mater. Sci. Eng., A 260(1–2), 161 (1999).
22. Cao, F., Wu, P., Ning, Z., Zhao, W., and Sun, J.: Shape-predicted model of spray forming rod under scanning atomization. Rare Met. 26, 3035 (2007).
23. Singer, A.R.E.: Principles of spray rolling of metals. Met. Mater. 4, 246250 (1970).
24. Cui, C., Fritsching, U., and Schulz, A.: Three-dimensional mathematical modeling and numerical simulation of billet shape in spray forming using a scanning gas atomizer. Metall. Mater. Trans. B 38, 333346 (2007).
25. Cui, C., Fritsching, U., Schulz, A., and Li, Q.: Mathematical modeling of spray forming process of tubular preforms part 2. Heat transfer. Acta Mater. 53, 27752784 (2005).


The study of preparation process of spray formed 7075/Al–Si bimetallic gradient composite plate

  • Lei Yu (a1), Fuyang Cao (a1), Liguo Hou (a1), Yandong Jia (a2), Hongxian Shen (a1), Haichao Li (a1), Zhiliang Ning (a1), Dawei Xing (a1) and Jianfei Sun (a1)...


Full text views

Total number of HTML views: 0
Total number of PDF views: 0 *
Loading metrics...

Abstract views

Total abstract views: 0 *
Loading metrics...

* Views captured on Cambridge Core between <date>. This data will be updated every 24 hours.

Usage data cannot currently be displayed