In the present study, electro-explosive spraying technology was used to prepare a multi-layer composite coating with a staggered spatial structure on a 45 steel substrate, and the mechanical properties and wear behavior of the coating were studied. The composite coating was prepared by spraying Mo as the bonding layer, then spraying high-carbon steel and aluminum bronze alternately as a functional coating. The cross-sectional morphology, surface morphology and the properties of the coating were analyzed with a scanning electron microscope (SEM), energy dispersive spectrometer (EDS), electron backscattered diffraction (EBSD) and a 3D profilometer. The bonding strength, friction and wear resistance of the coating were studied by the bonding strength experiment and by the friction and wear experiment. The results showed that it is feasible to prepare a composite coating with a sponge-like spatial structure with electro-explosive technology. There was metallurgical bonding as well as mechanical bonding between the adjacent coating layers. The composite coating had the advantages of uniform thickness, high compactness, high bonding strength and good wear resistance.
Corrosion is known as a breakdown effect that causes the deterioration of substances in enriched petroleum/gas conditions. This reaction occurs in all materials, which is highlighted in alloys. In the present study, the morphological properties, as well as the corrosion resistance behavior of the AISI1045 steel substrate coated with 321 austenitic stainless steel metal particulate fillers, were investigated. The electro-explosive spraying technique was employed to achieve a homogenous coating on the substrate surface. According to the results, the grain size of the 321 austenitic stainless steel coating layer was shrunk and reduced to 1–3 μm after the coating procedure. The coated layer also showed a homogenous and uniform thickness with an average value of 137 μm. Also, the average adhesion strength of 49.21 MPa was obtained between the sprayed coating and the substrate. The analytical analysis found the presence of Fe-Cr and Fe-Ni phases in the coating layer. The hardness of the original metal wire is 186 HV, and the microhardness of the coating after spraying is 232 HV. After subjecting the specimen to the corrosion examination, a 0.1961 mm/a corrosion rate was obtained for up to 120 h. Moreover, the corrosion products of CaCO3, Fe3O4, and MgFe2O4 were determined by XRD analysis. Furthermore, the observed results were further confirmed by the data obtained from EPMA and EDS evaluations. Hence, this study implies the beneficial role of electro-explosive sprayed alloy 321 austenitic stainless steel in creating a protective layer against corrosion on 45 steel substrate in an enriched oil/water environment.
In the present work, Fe/Cu composite coatings were fabricated by electro-explosive spraying technology (EEST), with good lubrication performance and high wear resistance. The microstructure and morphology were characterized by an energy-dispersive spectrometer (EDS), 3D digital microscope, and scanning electron microscope (SEM) coupled with electron backscattered diffraction (EBSD). Mechanical properties and tribological performance were measured using a micro Vickers hardness tester, universal testing machine, and universal friction and wear testing machine. The composite coating had low porosity with a minimum value of 0.7%, high microhardness with a maximum value of 729.9 HV0.2, high bonding strength with a maximum average value of 55.25 MPa, and good wear resistance and self-lubrication, and the ratio of soft metal and hard metal in the coatings was controllable. Under dry friction conditions, the friction reduction mechanism was that there were both metallic oxide particles and soft metal attached in the friction pairs. When the ratio of soft metal in the composite coating was higher, the self-lubricating performance of the coating was better, with adhesive wear as the main wear mechanism; when the ratio of hard metal was higher, the wear resistance was better and the wear mechanism was mainly abrasive wear.
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