Abstract
20 vol.% cubic boron nitride (cBN) dispersoid reinforced NiCrAl matrix nanocomposite coating was prepared by cold spray using mechanically alloyed nanostructured composite powders. The as-sprayed nanocomposite coating was annealed at a temperature of 750 °C to enhance the inter-particle bonding. Microstructure of spray powders and coatings was characterized. Vickers microhardness of the coatings was measured. Two-body abrasive wear behavior of the coatings was examined on a pin-on-disk test. It was found that, in mechanically alloyed composite powders, nano-sized and submicro-sized cBN particles are uniformly distributed in nanocrystalline NiCrAl matrix. Dense coating was deposited by cold spray at a gas temperature of 650 °C with the same phases and grain size as those of the starting powder. Vickers hardness test yielded a hardness of 1063 HV for the as-sprayed 20 vol.% cBN-NiCrAl coating. After annealed at 750 °C for 5 h, unbonded inter-particle boundaries were partially healed and evident grain growth of nanocrystalline NiCrAl was avoided. Wear resistance of the as-sprayed 20 vol.% cBN-NiCrAl nanocomposite coating was comparable to the HVOF-sprayed WC-12Co coating. Annealing of the nanocomposite coating resulted in the improvement of wear resistance by a factor of ~33% owing to the enhanced inter-particle bonding. Main material removal mechanisms during the abrasive wear are also discussed.
Similar content being viewed by others
References
S. Zhang, D. Sun, Y. Fu, and H. Du, Recent Advances of Superhard Nanocomposite Coatings: A Review, Surf. Coat. Technol., 2003, 167(2-3), p 113-119
J. Musil, Hard and Superhard Nanocomposite Coatings, Surf. Coat. Technol., 2000, 125(1-3), p 322-330
D.B. Witkin and E.J. Lavernia, Synthesis and Mechanical Behavior of Nanostructured Materials Via Cryomilling, Prog. Mater Sci., 2006, 51, p 1-60
M.S. El-Eskandarany, Mechanical Alloying for Fabrication of Advanced Engineering Materials Noyes Publications, William Andrew Publishing, Norwich, NY, 2001, p 1-113
L. Gao, X. Jin, H. Kawaoka, T. Sekino, and K. Niihara, Microstructure and Mechanical Properties of SiC-Mullite Nanocomposite Prepared by Spark Plasma Sintering, Mater. Sci. Eng. A, 2002, 334, p 262-266
Z.Q. Jin, K.H. Chen, J. Li, H. Zeng, S.F. Cheng, J.P. Liu, Z.L. Wang, and N.N. Thadhani, Shock Compression Response of Magnetic Nanocomposite Powders, Acta Mater., 2004, 52(8), p 2147-2154
A.N. Papyrin, A.P. Alkimov, and V.F. Kosarev. Experimental Study of Interaction of Supersonic Gas Jet with a Substrate Under Cold Spray Process, Proc. International Thermal Spray Conf., 2001, p 423-431
A.N. Papyrin, V.F. Kosarev, and S.V. Klinkov, On the Interaction of High Speed Particles with a Substrate Under the Cold Spraying, Proc. International Thermal Spray Conf., 2002, p 380-384
R.S. Lima, J. Karthikeyan, and C.M. Kay, Microstructural Characteristics of Cold-Sprayed Nanostructured WC-Co Coatings, Thin Solid Films, 2002, 416(1-2), p 129-135
H.J. Kim, C.H. Lee, and S.Y. Hwang, Fabrication of WC-Co Coatings by Cold Spray Deposition, Surf. Coat. Technol., 2005, 191(2-3), p 335-341
P.H. Gao, C.-J. Li, G.J. Yang, Y.G. Li, and C.X. Li, Influence of Substrate Hardness Transition on Built-Up of Nanostructured WC-12Co by Cold Spraying, Appl. Surf. Sci., 2010, 256(7), p 2263-2268
X.T. Luo, G.J. Yang, C.-J. Li, and K. Kondoh, High Strain Rate Induced Localized Amorphization in Cubic BN/NiCrAl Nanocomposite Through High Velocity Impact, Scr. Mater., 2011, 65(7), p 581-584
X.T. Luo, G.J. Yang, and C.-J. Li, Multiple Strengthening Mechanisms of Cold Sprayed cBNp/NiCrAl Composite Coating, Surf. Coat. Technol., 2011, 205(20), p 4808-4813
X.T. Luo and C.-J. Li, Thermal Stability of Microstructure and Hardness of Cold-Sprayed cBN/NiCrAl Nanocomposite Coating, J. Therm. Spray Technol., 2012, 21(3-4), p 578-585
X.T. Luo, C.-J. Li, and G.J. Yang, Correlations Between Milling Conditions and Iron Contamination, Microstructure and Hardness of Mechanically Alloyed Cubic BN Particle Reinforced NiCrAl Matrix Composite Powders, J. Alloys compd., 2013, 548, p 180-187
X.T. Luo, G.J. Yang, and C.-J. Li, Preparation of cBNp/NiCrAl Nanostructured Composite Powders by a Step-fashion Mechanical Alloying Process, Powder Technol., 2012, 217, p 591-598
J. Li and C. Ding, Determining Microhardness and Elastic Modulus of Plasma-Sprayed Cr3C2-NiCr Coatings Using Knoop Indentation Testing, Surf. Coat. Technol., 2001, 135(2-3), p 229-237
M.M. Lima, C. Godoy, J.C. Avelar-Batista, and P.J. Modenesi, Toughness Evaluation of HVOF WC-Co Coatings Using Non-Linear Regression Analysis, Mater. Sci. Eng. A, 2003, 357(1-2), p 337-345
G.K. Williamson and W.H. Hall, X-Ray Line Broadening from Filed Aluminium and Wolfram, Acta Metall., 1953, 1(1), p 22-31
H.X. Hu, S.L. Jiang, Y.S. Tao, T.Y. Xiong, and Y.G. Zheng, Cavitation Erosion and Jet Impingement Erosion Mechanism of Cold Sprayed Ni-Al2O3 Coating, Nucl. Eng. Des., 2011, 241(12), p 4929-4937
Q. Wang, N. Birbilis, H. Huang, and M.X. Zhang, Microstructure Characterization and Nanomechanics of Cold-Sprayed Pure Al and Al-Al2O3 Composite Coatings, Surf. Coat. Technol., 2013, 232(15), p 216-223
C. Feng, V. Guipont, M. Jeandin, O. Amsellem, F. Pauchet, R. Saenger, S. Bucher, and C. Iacob, B4C/Ni Composite Coatings Prepared by Cold Spray of Blended or CVD-Coated Powders, J. Therm. Spray Technol., 2012, 21(3-4), p 561-570
N.M. Melendez and A.G. McDonald, Development of WC-Based Metal Matrix Composite Coatings Using Low-Pressure Cold Gas Dynamic Spraying, Surf. Coat. Technol., 2013, 214, p 101-109
H. Koivuluoto, A. Coleman, K. Murray, M. Kearns, and P. Vuoristo, High Pressure Cold Sprayed (HPCS) and Low Pressure Cold Sprayed (LPCS) Coatings Prepared from OFHC Cu Feedstock: Overview from Powder Characteristics to Coating Properties, J. Therm. Spray Technol., 2012, 21(5), p 1065-1075
J.M. Shockley, H.W. Strauss, R.R. Chromik, N. Brodusch, R. Gauvin, E. Irissou, and J.G. Legoux, In Situ Tribometry of Cold-Sprayed Al-Al2O3 Composite Coatings, Surf. Coat. Technol., 2013, 215, p 350-356
E. Irissou, J.G. Legoux, B. Arsenault, and C. Moreau, Investigation of Al-Al2O3 Cold Spray Coating Formation and Properties, J. Therm. Spray Technol., 2007, 16(5-6), p 661-668
E. Sansoucy, P. Marcoux, L. Ajdelsztajn, and B. Jodoin, Properties of SiC-Reinforced Aluminum Alloy Coatings Poduced by the Cold Gas Dynamic Spraying Process, Surf. Coat. Technol., 2008, 202(6), p 3988-3996
K. Spencer, D.M. Fabijanic, and M.X. Zhang, The Influence of Al2O3 Reinforcement on the Properties of Stainless Steel Cold Spray Coatings, Surf. Coat. Technol., 2012, 206(14), p 3275-3282
M. Jafari, M.H. Enayati, M. Salehi, S.M. Nahvi, and C.G. Park, Microstructural and Mechanical Characterizations of a Novel HVOF-Sprayed WC-Co Coating Deposited from Electroless Ni-P Coated WC-12Co Powders, Mater. Sci. Eng. A, 2013, 578, p 46-53
S.B. Pitchuka, B. Basu, and G. Sundararajan, A Comparison of Mechanical and Tribological Behavior of Nanostructured and Conventional WC-12Co Detonation-Sprayed Coatings, J. Therm. Spray Technol., 2013, 4(22), p 478-490
E. Orowan, The Physical Basis of Adhesion, J. Frankl. Inst., 1970, 290(6), p 493-512
V. Richter and M.V. Ruthendorf, On Hardness and Toughness of Ultrafine and Nanocrystalline Hard Materials, Int. J. Refract. Met. Hard Mater., 1999, 17(1-3), p 141-152
C.-J. Li, W.Y. Li, and Y.Y. Wang, Formation of Metastable Phases in Cold-Sprayed Soft Metallic Deposit, Surf. Coat. Technol., 2005, 198(1-3), p 469-473
K.H. Kim, M. Watanabe, J. Kawakita, and S. Kuroda, Grain Refinement in a Single Titanium Powder Particle Impacted at High Velocity, Scr. Mater., 2008, 59(7), p 768-771
Y. Zou, W. Qin, E. Irissou, J.G. Legoux, S. Yue, and J.A. Szpunar, Dynamic Recrystallization in the Particle/Particle Interfacial Region of Cold-Sprayed Nickel Coating: Electron Backscatter Diffraction Characterization, Scr. Mater., 2009, 61(9), p 899-902
J.H. Schneibel, Processing, Properties, and Applications of Iron Ahuninides, The Minerals, Metals & Materials Society, Warrendale, PA, 1994, p 329
M.P. D’Evelyn and K. Zgonc, Elastic Properties of Polycrystalline Cubic Boron Nitride and Diamond by Dynamic Resonance Measurements, Diam. Relat. Mater., 1997, 6(5-7), p 812-816
L.L. Shaw, J. Villegas, J.Y. Huang, and S. Chen, Strengthening Via Deformation Twinning in a Nickel Alloy, Mater. Sci. Eng. A, 2008, 480, p 75-83
T. Sahraoui, S. Guessasma, M.A. Jeridane, and M. Hadji, HVOF Sprayed WC-Co Coatings: Microstructure, Mechanical Properties and Friction Moment Prediction, Mater. Des., 2010, 31(3), p 1431-1437
E. Rabinowicz, Friction and Wear of Materials, John Wiley and Sons, New York, 1965, p 168-169
J.F. Archard, Wear Theory and Mechanisms, Wear Control Handbook, American Society of Mechanical Engineers, New York, 1980, p 35-80
J. Pirso, M. Viljus, K. Juhani, and S. Letunovitš, Two-Body Dry Abrasive Wear of Cermets, Wear, 2009, 266(1-2), p 21-29
P.W. Leech and X.S. Li, Comparison of Abrasive Wear in Diamond Composites and WC-Based Coatings, Wear, 2011, 271(9-10), p 1244-1251
Acknowledgment
The project is supported by the National Science Found for Distinguish Young Scholar (No. 50725101).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Luo, XT., Yang, EJ., Shang, FL. et al. Microstructure, Mechanical Properties, and Two-Body Abrasive Wear Behavior of Cold-Sprayed 20 vol.% Cubic BN-NiCrAl Nanocomposite Coating. J Therm Spray Tech 23, 1181–1190 (2014). https://doi.org/10.1007/s11666-014-0092-3
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-014-0092-3