Influence of annealing on the structure and wear resistance of coatings produced by cold spraying of Al–SHS7574 powder mixture

Abstract

In present work, the possibility of fabricating a composite cold-sprayed coatings consisting of partially amorphous alloy reinforcing particles and an aluminum matrix was studied for the first time. A mixture of pure aluminum and SHS7574 powders in a ratio of 50/50 wt% was deposited on aluminum alloy substrates, which ensured the formation of high-quality coating with a porosity of less than 1%. The ratio of SHS7574 alloy to aluminum in the as-sprayed samples was nearly the same as in the initial powder mixture which indicates a similar efficiency of component deposition. Composite coatings were annealed in a vacuum furnace at 540 °C and 600 °C. Microstructure and phase composition of as-sprayed and annealed coatings were examined with XRD, SEM and EDX mapping. Post annealing of the coatings promoted the formation of a reaction layers around the Fe-based alloy particles consisting of Fe2Al5, Fe4Al13, Fe23B5, and Fe5C2 phases. The effect of annealing on the mechanical properties of the Al–SHS7574 coatings was determined by measuring hardness, nanohardness and wear resistance according to ASTM G 133–05. The increase in the samples’ hardness after annealing was associated with the formation of a reaction layers and increase in its thickness with rising annealing temperature. The coating annealed at 600 °C demonstrated the highest hardness due to the formation of thick brittle reaction layers. The preservation of the aluminum matrix with the simultaneous formation of thin reaction layers after annealing at 540 °C reduced the wear rate of the coating despite the moderate hardness.