Plasma-sprayed Al-based coating with WC-addition for excellent corrosion resistance and enhanced wear protection of Mg alloys

Thermal spray processes struggle to create a fully dense coating for corrosion protection in the as-sprayed state due to the poor inter-splat bonding. To tackle this problem, Al−15vol.%WC was utilized as the coating material and applied by atmospheric plasma spraying (APS) to produce a dense coating...

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Published inTransactions of Nonferrous Metals Society of China Vol. 34; no. 7; pp. 2275 - 2288
Main Authors RASHID, Haroon, LUO, Xiao-tao, DONG, Xin-yuan, ZHANG, Li, LI, Chang-jiu
Format Journal Article
LanguageEnglish
Published Elsevier Ltd 01.07.2024
Subjects
Al−WC coating
atmospheric plasma spray (APS)
corrosion resistance
deoxidization effect
self-metallurgical bonding
wear resistance
Al−WC coating
atmospheric plasma spray (APS)
deoxidization effect
corrosion resistance
wear resistance
self-metallurgical bonding
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Summary:Thermal spray processes struggle to create a fully dense coating for corrosion protection in the as-sprayed state due to the poor inter-splat bonding. To tackle this problem, Al−15vol.%WC was utilized as the coating material and applied by atmospheric plasma spraying (APS) to produce a dense coating with self-metallurgical inter-splat bonding. The results show that due to the in-flight particle deoxidizing effect by C element and self-metallurgical bonding of the overheated droplet (>1800 °C), dense coating without oxides inclusions is produced under optimized plasma spraying conditions. The fully dense Al−WC coating exhibits excellent corrosion resistance, with corrosion current density lower by four and two orders than that of Mg alloy substrate and bulk Al, respectively. Due to the inclusion of hard WC particles, the Al−WC coating presents one order improvement in wear resistance compared with the bulk Al.
ISSN:1003-6326
DOI:10.1016/S1003-6326(24)66540-4