Abstract
The Ni60 coatings were fabricated via induction cladding with Ni-coated TiC reinforcement particles using electroless plating to improve the coating quality. The corrosion and thermal fatigue behaviors of the H13, Ni60 coating and Ni-coated TiC particle-reinforced Ni60 coating in molten aluminum alloy were investigated. The results showed that Ni-coated TiC by electroless plating significantly improved preparation quality of ceramic particle-reinforced Ni60 coating. The weight loss of the received coating in molten aluminum alloy was about 25% of that of the H13 and 66% of that of the Ni60 coating. The corrosive mechanisms of the H13 steel and Ni60 coating in molten aluminum alloy involve the matrix phase Fe and Ni60 alloy being corroded by aluminum to form M-Al(M = Fe,Cr) intermetallic compounds (IMCs) and M-Al (M = Ni, Fe, Cr) IMCs, respectively. The corroded surface of the H13 steel showed flaky exfoliation happened at the Fe-(Fe,Cr) 2 Al 5 interface, while that of the Ni60 coating presented some large-scale cotton-like morphology due to fracture occurring at the Al-(Ni,Fe,Cr)Al 3 interface. The addition of the Ni-coated TiC particles effectively reduced further dissolution of Fe, Cr and Ni of the received coating into molten aluminum alloy, and changed interface morphology of Al-(Ni,Fe,Cr)Al 3 interface from cotton like to little serrate like, and significantly enhance the corrosive resistance to molten aluminum alloy. The thermal fatigue failure mode of the H13 steel is mainly surface oxidation and lamellar spalling of the oxide layer, and the thermal fatigue cracks of the Ni60 coating initiated in the oxide layer of M-Al (M = Ni, Fe, Cr) IMCs and propagated longitudinally under the action of thermal stress, while cracks of the Ni-coated TiC-reinforced Ni60 coating originated at the junction of non-eroded titanium carbide and eroded Ni60 alloy at the erosion front and propagated in the TiC particles and coating matrix phases. • Process combination of induction cladding and electroless plating • Induction-clad Ni60 coatings with Ni-coated TiC reinforcement particles using electroless plating • Significant improvement of preparation quality of TiC-reinforced Ni60 coating using electroless plating • Corrosion and thermal fatigue behaviors of H13, Ni60 coating and Ni-coated TiC-Ni60 coating in molten aluminium alloy
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