Abstract
Zn-Ni-Al2O3 composite coatings with different Ni contents were fabricated by low-pressure cold spray (LPCS) technology. The effects of the Ni content on the microstructural and mechanical properties of the coatings were investigated. According to X-ray diffraction patterns, the composite coatings were primarily composed of metallic-phase Zn and Ni and ceramic-phase Al2O3. The energy-dispersive spectroscopy results show that the Al2O3 content of the composite coatings gradually decreased with increasing of Ni content. The cross-sectional morphology revealed thick, dense coatings with a wave-like stacking structure. The process of depositing Zn and Ni particles and Al2O3 particles by the LPCS method was examined, and the deposition mechanism was demonstrated to be mechanical interlocking. The bond strength, micro hardness and friction coefficient of the coatings did not obviously change when the Ni content varied. The presence of Al2O3 and Ni increased the wear resistance of the composite coatings, which was higher than that of pure Zn coatings, and the wear mechanism was abrasive and adhesive wear.
Highlights
Zn-Ni alloy coatings have been widely used in a range of industrial applications due to their superior corrosion resistance [1]
The roughnesses of coatings slightly change with an increasing Ni content, mainly due to the influence of the coating thickness
Zn-Ni-Al2O3 composite coatings with different Ni contents were successfully fabricated on Q235 substrate by the low-pressure cold spray (LPCS) technique, and their composition, microstructure, mechanical properties and tribological behavior were examined
Summary
Zn-Ni alloy coatings have been widely used in a range of industrial applications due to their superior corrosion resistance [1]. These coatings are employed as sacrificial coatings for steel because they preferentially dissolve in corrosive media and result in a surface layer of products with low solubility that slows the corrosion reaction and protects the substrate underneath. Zn-Ni composite coatings are prepared on the surface of materials and components using electroplating [8,15], hot dip coating [16,17] and thermal spraying methods [18,19,20,21].
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