Self-organized high-hardness thermal spray coatings

I McCue, B Gaskey, M Brupbacher… - Available at SSRN …, 2021 - papers.ssrn.com
I McCue, B Gaskey, M Brupbacher, WM Buchta, A Chuang, K Xie, WCH Kuo, J Erlebacher
Available at SSRN 3793930, 2021papers.ssrn.com
We present a new dealloying-based technique to form fully-dense and high-hardness metal
composite coatings. By depositing then heat treating a TiCr alloy coating on a Ni-base
superalloy, a eutectic reaction occurs at the coating/substrate interface, which drives
spontaneous pattern formation in both alloys analogous to liquid metal dealloying. The
coating exhibits a significantly higher hardness (15 GPa) than both the starting alloy (3.7
GPa) and precursor coating (6 GPa), measured by micro-and nanoindentation, while …
Abstract
We present a new dealloying-based technique to form fully-dense and high-hardness metal composite coatings. By depositing then heat treating a TiCr alloy coating on a Ni-base superalloy, a eutectic reaction occurs at the coating/substrate interface, which drives spontaneous pattern formation in both alloys analogous to liquid metal dealloying. The coating exhibits a significantly higher hardness (15 GPa) than both the starting alloy (3.7 GPa) and precursor coating (6 GPa), measured by micro-and nanoindentation, while maintaining the ability to plastically deform during micro-indentation experiments without apparent cracking or spallation. The flexibility and scalability of the dealloying process used here demonstrates a promising route towards protective coatings for structural alloys.
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