Effect of powder feed rate on the mechanical properties of WC-5 wt%Ni coatings deposited using low pressure cold spray

2016 
Abstract WC-5 wt%Ni coatings were fabricated onto 3CR12 stainless steel plates using low pressure cold spray deposition. The powder feed rate of the volumetric feeder was varied at 50% (23.6 rpm, 6.8 ± 1 g min − 1 ), 75% (35.7 rpm, 10.1 ± 0.9 g min − 1 ), and 100% (58.9 rpm, 15 ± 1.1 g min − 1 ), and the resulting influence on the mechanical properties of the coatings was investigated. The results were analyzed using a two-parameter Weibull distribution and linear regression analysis. A new parameter to quantify WC particle refinement is proposed. A powder feed rate of 75% produced the best coating properties, achieving a high hardness (2.56 GPa), low porosity (0.55%), high interfacial toughness (12.61 MPa m 0.5 ), high Young's modulus (69.23 GPa), and good fracture toughness (2.81 MPa m 0.5 ). This feed rate appeared to be the optimum deposition parameter to produce dense coatings, achieving a high level of Ni plastic deformation and a high amount of refined WC particles, which are too small to cause significant erosion during impact, and are therefore better able to be retained by the ductile binder.
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