A Novel Nano-Composite Wire Material: The Low Cost and Enhanced Properties Coating Design

Abstract

Due to their enhanced mechanical properties and high range applications in severe environments use, there is ongoing research in the area of amorphous metallic glasses and nanostructured materials. The science and mechanisms leading to these exceptional properties are discussed herein. The arc sprayed coatings produced for study in this paper show remarkable performance and are analyzed in-depth using advanced characterization techniques such as X-ray diffraction (XRD), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Additional analysis of the mechanical properties of the coatings show enhanced strength and hardness, good wear and corrosion properties, along with high temperature corrosion and oxidation resistance.

Nanocomposite coatings: thermal spray processing, microstructure and performance

“…94,95 Figure 11 shows the cross-section and nanoparticle distribution in a nanocomposite cored wire. 96 There are several variations of cored nanocomposite wires, characterised by the type and structure of the core filling and metal sheath materials. The construction of the simplest and most common cored wire is shown in Fig.…”

“…In general, conventional flame spray and HVOF processes are employed to deposit cermets of polymer matrix materials such as Feepoxy, Nylon-nanodiamond, Nylon-SiO 2 , Al 2 O 3 -NiCr, [159][160][161] On the other hand, wire arc sprayed nanocomposite coatings have been limited by the commercial availability of nanostructured feedstock, and are typically formed from metal alloy cored wire that forms carbides, borides, and/or oxides through in-flight reaction and embedment within the metallic matrix. 96,[162][163][164][165][166] Cold spray is typically used to deposit composites with a ductile phase to encapsulate ceramic particulates because of its high particle velocity and the lack of a molten phase; e.g. Al…”

“…94,95 Figure 11 shows the cross-section and nanoparticle distribution in a nanocomposite cored wire. 96…”

“… a Cross-section of nanocomposite cored wire (Praxair Surface Technologies Inc., Indianapolis, IN, USA) and b high magnification SEM micrograph showing the homogeneous distribution of nanocomposite particles within the cored wire. Reproduced from Georgieva et al 96 with permission from ASM International…”

“…159–161 On the other hand, wire arc sprayed nanocomposite coatings have been limited by the commercial availability of nanostructured feedstock, and are typically formed from metal alloy cored wire that forms carbides, borides, and/or oxides through in-flight reaction and embedment within the metallic matrix. 96,162–166…”