Effect of Substrate Type on Deposition Behavior and Wear Performance of Ni-Coated Graphite/Al Composite Coatings Deposited by Cold Spraying

doi:10.1016/j.jmst.2016.11.016

Abstract

Abstract:

This work focused on the deposition characteristics and wear behavior of Ni-coated graphite mixed with 40 vol.% Al (Ni-Gr/Al) composite coatings sprayed on an Al alloy and a steel substrate by cold spraying (CS). The morphology of the flattened Ni-Gr particles was examined by single-impact tests. Cross-sectional microstructure and wear performance of the Ni-Gr/Al composite coatings were studied. Results showed that a larger number of Ni-Gr particles were finally bonded with the steel substrate, whereas many craters existed on the Al alloy substrate after the single-impact tests. The coating on the steel substrate had a high thickness, high graphite content and low coefficient of friction (COF) compared to those on the Al alloy substrate. In addition, the CS coatings presented a homogeneous distribution and uniform morphology of graphite, and a comparative COF to that of conventional thermal sprayed coatings. It was shown that CS could avoid the decomposition and transformation of graphite phase.

Key words: Cold spraying, Ni-coated graphite, Deposition behavior, Microstructure, Wear performance

Huang Chunjie, Li Wenya, Xie Yingchun, Planche Marie-Pierre, Liao Hanlin, Montavon Ghislain. Effect of Substrate Type on Deposition Behavior and Wear Performance of Ni-Coated Graphite/Al Composite Coatings Deposited by Cold Spraying[J]. J. Mater. Sci. Technol., 2017, 33(4): 338-346.

Figures/Tables 8

Fig. 1. SEM morphologies of (a) the used powder Ni-Gr, (b) the cross-section of the Ni-G particles and (c) the used Al powder. The size distribution of the (d) Ni-Gr powder and (e) Al powder.

Fig. 2. BSE-SEM morphologies of the Ni-Gr powders impacted on Al alloy 2024 substrate (a and b) and steel substrate (c and d) after single impacts. (b) and (d) are higher magnification. (e) EDS results of the points in (b) and (d).

Fig. 3. SEM surface morphology of the Ni-Gr/Al composite coatings deposited on Al alloy 2024 substrate (a and b) and steel substrate (c and d). (b) and (d) are captured at higher magnifications.

Fig. 4. Cross-sectional SE-SEM morphology of the as-sprayed Ni-Gr/Al composite coating deposited on Al alloy 2024 substrate (a-c) and steel substrate (d-f). (c) and (f) are higher magnification showing the interface morphologies.

Fig. 5. Coating thickness (a) and Gr content (b) in the Ni-Gr/Al composite coating deposited on Al alloy 2024 and steel substrates, respectively.

Fig. 6. Micro-hardness of the Ni-Gr/Al composite coating deposited on Al alloy 2024 and steel substrates, respectively.

Fig. 7. COF of the Ni-Gr/Al composite coating as a function of sliding time at room temperature.

Fig. 8. Worn surface morphology of the Ni-Gr/Al composite coating (a and b) and EDS results of a point (c) deposited on Al alloy 2024 substrate, and worn surface morphology of the Ni-Gr/Al composite coating (d and e) and EDS results of a point (f) deposited on steel substrate.

References

[1]	Y. Wang, L. Zhang, Y.J. Hu, C.H. Li,J. Mater. Sci. Technol, 31(2015), pp. 901-906
[2]	J.J. Tang, K. Liu, Q.Z. Yang, Y.H. Wang, P. Zhang, Y. Wang, L. Zhao, Q.Q. Fu, Z.H. Han, Y. Bai,Surf. Coat. Technol, 252(2014), pp. 48-55
[3]	J. Yang, Y.J. Zhang, X.Q. Zhao, Y.L. An, H.D. Zhou, J.M. Chen, G.L. Hou,Tribol. Int, 90(2015), pp. 96-103
[4]	C.G. Xu, L.Z. Du, B. Yang, W.G. Zhang,Corros. Sci, 53(2011), pp. 2066-2074
[5]	C. Xu, L. Du, B. Yang, W.G. Zhang,Surf. Coat. Technol, 205(2011), pp. 4154-4161
[6]	S.P. Song, C. Li, Z.H. Ji,Appl. Mech. Mater, 164(2012), pp. 55-58
[7]	C.E. Fanning, T.A. Blanche,Wear, 265(2008), pp. 1076-1086
[8]	B. Yin, G. Liu, H. Zhou, J. Chen, F. Yan,Tribol. Lett, 37(2010), pp. 463-475
[9]	H. Zhou, C. Zhang, W. Wang, M. Yasir, L. Liu,J. Mater. Sci. Technol, 31(2015), pp. 43-47
[10]	C.J. Li, W.Y. Li,Surf. Coat. Technol, 167(2003), pp. 278-283
[11]	W.Y. Li, H.L. Liao, C.J. Li, G. Li, C. Coddet, X.F. Wang,Appl. Surf. Sci, 253(2006), pp. 2852-2862
[12]	W.Y. Li, C. Zhao, H.L. Liao, J.L. Li, C. Coddet,Surf. Coat. Technol, 202(2008), pp. 4855-4860
[13]	X.T. Luo, G.J. Yang, C.J. Li, K. Kondoh,Scr. Mater, 65(2011), pp. 581-584
[14]	W.Y. Li, G. Zhang, X.P. Guo, H.L. Liao, C. Coddet,Adv. Eng. Mater, 9(2007), pp. 577-583
[15]	X.M. Meng, J.B. Zhang, J. Zhao, Y.L. Liang, Y.J. Zhang,J. Mater. Sci. Technol, 27(2011), pp. 809-815
[16]	M. Yandouzi, S. Gaydos, D. Guo, R. Ghelichi, B. Jodoin,J. Therm. Spray Technol, 23(2014), pp. 1281-1290
[17]	R. Jones, N. Matthews, C.A. Rodopoulos, K. Cairns, S. Pitt,Int. J. Fatigue, 33(2011), pp. 1257-1267
[18]	C. Feng, V. Guipont, M. Jeandin, O. Amsellem, F. Pauchet, R. Saenger, S. Bucher, C. Iacob,J. Therm. Spray Technol, 21(2012), pp. 561-570
[19]	H. Na, G. Bae, S. Shin, S. Kumar, H. Kim, C. Lee,Compos. Sci. Technol, 69(2009), pp. 463-468
[20]	H.J. Kim, D.H. Jung, J.H. Jang, C.H. Lee,Thermal Spray 2006 —Building on 100 Years of Success, (2006), pp. 15-18
[21]	S. Grigoriev, A. Okunkova, A. Sova, P. Bertrand, I. Smurov,Surf. Coat. Technol, 268(2015), pp. 77-84
[22]	W.Y. Li, R.R. Jiang, C.J. Huang, Z.H. Zhang, Y. Feng,Mater. Des, 65(2015), pp. 757-761