Abstract
Diamond-reinforced metal matrix composites (DMMC) have great potential for wear-resistance applications due to the superior hardness imparted by diamond. Atmospheric plasma spraying involving axial injection of suitable feedstock is a convenient pathway to fabricate DMMC coatings for tribological applications. In this paper, thick DMMC coatings were deposited by plasma spraying Ni–P clad diamond particles under varying spray conditions. It was found that the phase characteristics of DMMC coatings as well as extent of diamond retention and fragmentation were significantly influenced by spray conditions such as, stand-off distance (SOD) and carrier gas flow rate (CGFR). Mechanical characterization (by micro-indentation) on all DMMC coatings developed in this work showed that coatings sprayed with longer SOD and higher CGFR has relatively higher hardness than other two coatings. However, on nanoindentation, the diamond hardness was found overestimated due to effect of diamond roughness on fragmentation. Ball-on-disc wear testing showed excellent tribological properties in all cases, with enhanced wear performance being noted when more diamond is retained in the coating.
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