Abstract

A nano-ZrB2 reinforced CoNiCrAlY composite coating with highly dense structures was prepared by HVOF via a step-fashion mechanical alloying (MA) powder process. The microstructure, mechanical properties, high-temperature oxidation and wear resistance were analyzed. Results show that a high-quality CoNiCrAlY-ZrB2 powder with expected powder size and homogenous dispersion of nano-ZrB2 can be obtained by the 35 h step-fashion MA. The addition of nanoscale ZrB2 greatly improves mechanical properties of CoNiCrAlY-ZrB2 coating, while the low content β-NiAl phase hinders its oxidation performance. Due to the formation of “upper enamel layer” during sliding process and the excellent hardness/fracture toughness, the wear resistance of CoNiCrAlY-ZrB2 coating (2.46 ×10−14 m3·N−1·m−1) at 1000 ℃ is much better than that of CoNiCrAlY coating (1.9 ×10−12 m3·N−1·m−1), showing that CoNiCrAlY-ZrB2 coating has a high potential for protecting hot parts.

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