Abstract
Hierarchical structure has been proposed as an effective strategy for improving mechanical properties in many traditional alloy systems. In this work, using a similar structural design strategy, hierarchical structured Fe-based amorphous coatings comprising two layers with different porosities were successfully prepared by controlling the thermal spraying process parameters. Impact test revealed that hierarchical structure designed coatings exhibited enhanced impact resistance than that of the monolithic structured counterpart. Microstructure examinations demonstrated that compared with the monolithic structured coating, the introduction of hierarchical structure could not only effectively passivate the cracks, but also deflect the propagation path of the cracks, which directly or indirectly enhanced crack propagation resistance. Based on this, theoretical analysis and finite element simulations were systematically performed to reveal the intrinsic reasons for the improved impact toughness in hierarchical structured coatings, centering around the influence of hierarchical structure on the absorption rate of impact energy and the stress distribution of coating during the impact process. In summary, the current study opens another promising window to enhance the impact resistance of amorphous coatings.
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