Tribological behavior of steel-based composite coatings produced by cold spray

Abstract

This study investigates the microstructure, the mechanical properties, the topography and the tribological behavior of a composite coating obtained by cold spray, as a potential candidate for its use in internal combustion engines in the automotive sector. The coating consists of a 410 L matrix and M2 tool steel reinforcements. For comparison, a single component 410 L cold sprayed coating and a wire arc coating, used in some of today's car engines, are also studied. Post-spraying, the coatings underwent specific surface finishing. Their microstructure and topographies were observed. A lubricated reciprocating sliding test was performed, resulting in an exceptionally low friction coefficient and negligible wear, even in harsh conditions for the composite coating. The analyses revealed that the surface finish creates protuberances due to the presence of hard M2 particles, activating a series of mechanisms bringing to the stabilization of a tribofilm. This can be considered responsible for the exceptional tribological properties observed. This study proposes the application of surface textures with protuberances, in particular, their use in lubricated contacts in presence of fully formulated oils, and how cold spray is a suitable process to easily produce them.