Skip to main content
SpringerLink
Log in

Microstructure and mechanical properties of twin-wire arc sprayed Ni-Al composite coatings on 6061-T6 aluminum alloy sheet

  • Published:
International Journal of Minerals, Metallurgy, and Materials Aims and scope Submit manuscript

Abstract

We have systematically studied the microstructure and mechanical properties of Ni-5wt%Al and Ni-20wt%Al composite coatings fabricated on 6061-T6 aluminum alloy sheet by twin-wire arc spraying under different experimental conditions. The abrasive wear behavior and interface diffusion behavior of the composite coatings were evaluated by dry/wet rubber wheel abrasive wear tests and heat treatment, respectively. Experimental results indicate that the composite coatings exhibit features of adhesive wear. Besides, the Vickers microhardness of NiAl and Ni3Al intermetallic compounds is relatively larger than that of the substrate, which is beneficial for enhancing the wear resistance. With the increase of annealing temperature and time, the interface diffusion area between the Ni-Al coating and the substrate gradually expands with the formation of NiAl3 and Ni2Al3 phases, and is controlled by diffusion of aluminum atoms. The grain growth exponent n of diffusion kinetics of the Ni-Al coating, calculated via a high-temperature diffusion model at 400, 480, and 550°C, is between 0.28 and 0.38. This satisfies the cubic law, which is consistent with the general theoretical relationship of high-temperature diffusion.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. J.H. Jules and P.R. David, High Profile Non-Skid Deck Coating Composition, USA Patent, Appl. 5686507, 1997.

    Google Scholar 

  2. C. Wilhelm, G. LaCaille, N. Wright, N. Ward, C. Shu, R. Painter, C. Vinquist, P. Stoyanov, E.W. Lee, D. Piatkowski, J. McLennan, J. Ogren, C. Kumor, and O.S. Es-Said, Mechanical properties and microstructure characterization of coated AM2 Al 6061-T6 mats exposed to simulated thermal blast, Eng. Fail. Anal., 16(2009), No. 1, p. 1.

    Article  Google Scholar 

  3. I. Gedzevicius and A.V. Valiulis, Analysis of wire arc spraying process variables on coatings properties, J. Mater. Process. Technol., 175(2006), No. 1–3, p. 206.

    Article  Google Scholar 

  4. L.M. Zhang, B.W. Liu, and D.B. Sun, Preparation and properties of the Ni-Al/Fe-Al intermetallics composite coating produced by plasma cladding, Int. J. Miner. Metall. Mater., 18(2011), No. 6, p. 725.

    Article  Google Scholar 

  5. R.B. Feng, S.J. Gong, and Z.P. Wang, Contrastive study of wear and friction on Ni-5wt%Al and Ni-20wt%Al coating, Rare Met. Mater. Eng., 40(2011), No. S3, p. 269.

    Google Scholar 

  6. D. Peng, J. Shen, Q. Tang, C.P. Wu, and Y.B. Zhou, Effects of aging treatment and heat input on the microstructures and mechanical properties of TIG-welded 6061-T6 alloy joints, Int. J. Miner. Metall. Mater., 20(2013), No. 3, p. 259.

    Article  Google Scholar 

  7. J.X. Wang, J.F. Sun, and Z.P. Wang, Effect of heat treatment to Ni-20wt.%Al coating diffusion, Adv. Mater. Res., 621(2013), p. 75.

    Article  Google Scholar 

  8. J.X. Wang, J.F. Sun, and Z.P. Wang, Effect of heat treatment to twin-wire arc spraying Ni-5wt.%Al coating on 6061-T6 aluminum alloy diffusion, Adv. Mater. Res., 631–632(2013), p. 424.

    Google Scholar 

  9. J.X. Wang, J.S. Liu, J.F. Sun, and Z.P. Wang, Microstructure and mechanical properties of twin-wire arc spraying Ni-5wt.% Al coating on 6061-T6 aluminum alloy, China Weld, 22(2013), No. 2, p. 49.

    Google Scholar 

  10. H.F. Li, S.F. Tao, Z.H. Zhou, L.D. Sun, A. Hesnawi, and S.K. Gong, Element diffusion during fabrication of EB-PVD NiAl coating and its 1100°C isothermal oxidation behavior (II), Surf. Coat. Technol., 201(2007), No. 15, p. 6589.

    Article  Google Scholar 

  11. S.C. Mishra, A. Satapathy, M. Chaithanya, P.V. Ananthapadmanabhan, and K.P. Sreekumar, Wear characteristics of plasma sprayed nickel-aluminum composite coatings, J. Reinf. Plast. Compos., 28(2009), No. 23, p. 2931.

    Article  Google Scholar 

  12. P. BiaŁucki and S. Kozerski, Study of adhesion of different plasma-sprayed coatings to aluminium, Surf. Coat. Technol., 201(2006), No. 5, p. 2061.

    Article  Google Scholar 

  13. K. Gong, H.L. Luo, Z.F. Zhou, Z.L. Tian, L. Nyborg, and C.H. Li, Wear evaluation on Ni3Al/MnS composite related to metallurgical processes, J. Iron Steel Res. Int., 19(2012), No. 7, p. 46.

    Article  Google Scholar 

  14. J.L. Mo and M.H. Zhu, Sliding tribological behaviors of PVD CrN and AlCrN coatings against Si3N4 ceramic and pure titanium, Wear, 267(2009), No. 5–8, p. 874.

    Article  Google Scholar 

  15. G.S. Fox-Rabinovich, B.D. Beake, J.L. Endrino, S.C. Veldhuis, R. Parkinson, L.S. Shuster, and M.S. Migranov, Effect of mechanical properties measured at room and elevated temperatures on the wear resistance of cutting tools with TiAlN and AlCrN coatings, Surf. Coat. Technol., 200(2006), No. 20–21, p. 5738.

    Article  Google Scholar 

  16. Y.Z. Xing, Q.L. Wei, C.P. Jiang, and J.M. Hao, Abrasive wear behavior of cast iron coatings plasma-sprayed at different mild steel substrate temperatures, Int. J. Miner. Metall. Mater., 19(2012), No. 8, p. 733.

    Article  Google Scholar 

  17. G.A. López, S. Sommadossi, P. Zieba, W. Gust, and E.J. Mittemeijer, Kinetic behaviour of diffusion-soldered Ni/Al/Ni interconnections, Mater. Chem. Phys., 78(2003), No. 2, p. 459.

    Article  Google Scholar 

  18. P. Nash, M.F. Singleton, and J.L. Murray, Phase Diagrams of Binary Nickel Alloys, ASM International, United States, 1991, p. 394.

    Google Scholar 

  19. H.A. Pour, M. Lieblich, S.G. Shabestari, and M.T. Salehi, Influence of pre-oxidation of NiAl intermetallic particles on thermal stability of Al/NiAlp composites at 500°C, Scripta Mater., 53(2005), No. 8, p. 977.

    Article  Google Scholar 

  20. D. Singh, P. Nageswara Rao, and R. Jayaganthan, Microstructures and impact toughness behavior of Al 5083 alloy processed by cryorolling and afterwards annealing, Int. J. Miner. Metall. Mater., 20(2013), No. 8, p. 759.

    Article  Google Scholar 

  21. S. Bose, High Temperature Coatings, Elsevier Inc., New York, 2007, p. 1.

    Book  Google Scholar 

  22. R. Pretorius, R. de Reus, A.M. Vredenberg, and F.W. Saris, Use of the effective heat of formation rule for predicting phase formation sequence in Al Ni systems, Mater. Lett., 9(1990), No. 12, p. 494.

    Article  Google Scholar 

  23. J.P. Lei, X.L. Dong, F.G. Zhao, B. Lv, H. Huang, and M.K. Lei, Prediction of the primary intermetallic compound nanoparticles formed in Fe(Ni)-Sn system, Acta Metall. Sin., 44(2008), No. 8, p. 922.

    Google Scholar 

  24. M. Jain and S.P. Gupta, Formation of intermetallic compounds in the Ni-Al-Si ternary system, Mater. Charact., 51(2003), No. 4, p. 243.

    Article  Google Scholar 

  25. A.M. Rashidi, Isothermal oxidation kinetics of nanocrystalline and coarse grained nickel: experimental results and theoretical approach, Surf. Coat. Technol., 205(2011), No. 17–18, p. 4117.

    Article  Google Scholar 

  26. P.C. Tsai, C.F. Tseng, C.W. Yang, I.C. Kuo, Y.L. Chou, and J.W. Lee, Thermal cyclic oxidation performance of plasma sprayed zirconia thermal barrier coatings with modified high velocity oxygen fuel sprayed bond coatings, Surf. Coat. Technol., 228(2013), No. S1, p. S11.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Ji-xiao Wang & Jian-fei Sun

  2. Harbin Welding Institute, China Academy of Machinery Science & Technology, Harbin, 150028, China

    Ji-xiao Wang

  3. School of Materials Science and Engineering, Inner Mongolia University of Technology, Hohhot, 010051, China

    Jing-shun Liu

  4. National Laboratory of Solid State Microstructures & Department of Materials Science and Engineering, Nanjing University, Nanjing, 210093, China

    Lun-yong Zhang

  5. College of science, Civil Aviation University of China, Tianjin, 300300, China

    Zhi-ping Wang

Authors
  1. Ji-xiao Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jing-shun Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Lun-yong Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jian-fei Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zhi-ping Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Ji-xiao Wang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, Jx., Liu, Js., Zhang, Ly. et al. Microstructure and mechanical properties of twin-wire arc sprayed Ni-Al composite coatings on 6061-T6 aluminum alloy sheet. Int J Miner Metall Mater 21, 469–478 (2014). https://doi.org/10.1007/s12613-014-0931-8

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12613-014-0931-8

Keywords

Search

Navigation