This study analyzed the mechanical properties of cold-sprayed Cr3C2-25(Ni20Cr) blended with Ni-graphite as a solid lubricant deposited on 7075 aluminum alloy substrate. To optimize the coating properties, different sets of parameters (graphite content in feedstock, process gas composition, spraying distance, and traverse gun speed) were tested in the frame of the Taguchi experiment. The cold-sprayed coatings were evaluated for their chromium carbide and graphite content, hardness, and coefficient of friction. Analysis of the microstructure of the deposited coatings revealed that graphite as a soft and brittle component fills all voids in the coating and its quantity depends on its content in the feedstock. The experimental results show that the composition of the process gas has the greatest impact on the Cr3C2 content in the coating and the proportion of graphite in the sprayed blend directly affects its hardness. In the case of the coefficient of friction, the most significant parameters were the graphite content in the sprayed blend, the spraying distance, and process gas composition. The conducted verification experiment with the optimum parameter values allowed a coating with the highest hardness and the lowest coefficient of friction to be obtained.
Nanostructured and composite WC-12Co coatings were prepared by means of the supersonic spray process (HVOF). The microstructure and composition of WC-12Co nanostructured powder were analyzed by scanning electron microscope (SEM) and transmission electron microscope (TEM). Investigations revealed nano grains of WC with the size in the range of 50-500 nm. The nanostructured sprayed coating was analysed by SEM and phase composition was investigated by X-ray diffractometer (XRD). A denser coating structure with higher hardness was observed compared to conventional coating with a small amount of W2C, WC1−x, W and some amorphous phase. Young’s modulus and hardness were determined by depth sensing indentation in HVOF sprayed WC-12Co nanostructured coatings. Results were compared to conventional coatings and the relevance of the nanostructure was analyzed. An indentation size effect was observed on the polished surface and cross-section of both coatings. Data provided by indentation tests at maximum load allow to estimate hardness and elastic modulus. Enhanced nanomechanical properties of conventional coating in comparison to nanostructured one were observed. Nanostructured coatings WC-12Co (N) revealed significantly better corrosion resistance.
Cold sprayed Ni coatings offer new possibilities for repairing damaged and mis-machined components. The morphology of the powder particles and grain-size distribution have a significant influence on the particles' behaviour during compaction and on the properties of the coating. In this study, two Ni powders with different morphology and grain-size distribution were cold sprayed on a 7075 Al alloy substrate. The first powder, Ni HR, had an irregular spherical shape, whereas the second, Ni E, possessed a dendritic shape. SEM and TEM investigations revealed differences in the microstructure and properties of the Ni cold-sprayed coatings. The coating sprayed using the dendritic powder revealed enhanced mechanical properties and the surface had half the roughness of the Ni coatings deposited using the irregular spheroidal powder.
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