Comparative study of morphology and surface composition of Al–Cr–Fe alloy powders produced by water and gas atomisation technologies

Abstract The morphology and surface composition of Al–Cr–Fe alloy powders of 0–63 and 63–100 μm size fractions, produced by gas and water atomisation, have been studied by scanning electron microscopy and Auger electron spectroscopy. While gas atomised particles are of spherical shape, water atomised powders are usually irregular in shape with a complex branched relief. The morphology and composition of surface oxides have been estimated. The surface oxide film is composed of aluminium oxides/hydroxides and contains no Fe and Cr atoms. Two to five water molecules are associated with one Al2O3 molecule on the surface of powders. The surface oxide film has a non-uniform thickness, with thick oxide islands separated by thinner oxide film. The parameters of the surface film morphology, such as the island coverage, the oxygen content and the thin film thickness, depend on the atomisation technology used and powder size fraction. Heavily and weakly oxidised powder groups present in all powder fractions are distinguished by Auger spectra analysis. Relationships between heavily and weakly oxidised powder groups are discussed as a function of atomisation technology and size fraction.