Effect of α-Al2O3 on the properties of cold sprayed Al/α-Al2O3 composite coatings on AZ91D magnesium alloy

Composite coatings using pure Al powder blended with α-Al₂O₃ as feedstock were deposited on AZ91D magnesium alloy substrates by cold spray (CS). The content of α-Al₂O₃ in the feedstock was 25 wt.% and 50 wt.%, respectively. The effects of α-Al₂O₃ on the porosity, microhardness, adhesion and tensile strength of the coatings were studied. Electrochemical tests were carried out in neutral 3.5 wt.% NaCl solution to evaluate the effect of α-Al₂O₃ on the corrosion behavior of the coatings. The results showed that the composite coatings possessed lower porosity, higher adhesion strength and tensile strength than cold sprayed pure Al coating. The corrosion current densities of the composite coatings were similar to that of the pure Al coating and much higher than that of bare AZ91D magnesium alloy.     

Effect of Ni-to-Fe ratio on structure and properties of Ni-Fe-B-Si-Nb coatings fabricated by laser processing

Ni-Fe-B-Si-Nb coatings have been deposited on mild steel substrates using high power laser cladding process followed by laser remelting. The influence of Ni-to-Fe concentration ratio in (Ni_100−xFe_x)₆₂B₁₈Si₁₈Nb₂ (x = 55, 50, 45 and 40) powders on the phase composition and microstructure is analyzed by X-ray diffraction, scanning- and transmission-electron microscopies. The microhardness and corrosion resistance properties of the coatings are also measured. The results reveal that amorphous matrix layers are obtained for all coatings. The increase of the Ni-to-Fe ratio can promote the formation of γ(Fe-Ni) phase and decrease the formation of Fe₂B phase and α-Fe phase. The coating with 1:1 ratio of Ni-to-Fe exhibits the highest microhardness of 1200 HV_0.5 and superior corrosion resistance property due to its largest volume fraction of amorphous phase in the coating. Higher or lower than 1:1 ratio of Ni-to-Fe may result in lower amorphous forming ability. However, even that the coating with ratio of 3:2, shows a minimum of microhardness, it shows a better corrosion resistance than other two coatings.     

Laser induction hybrid rapid cladding of WC particles reinforced NiCrBSi composite coatings

In order to investigate the microstructure characteristics and properties of Ni-based WC composite coatings containing a relatively large amount of WC particles by laser induction hybrid rapid cladding (LIHRC) and compare to the individual laser cladding without preheating, Ni60A + 35 wt.% WC composite coatings are deposited on A3 steel plates by LIHRC and the individual laser cladding without preheating. The composite coating produced by the individual laser cladding without preheating exhibits many cracks and pores, while the smooth composite coating without cracks and pores is obtained by LIHRC. Moreover, the cast WC particles take on the similar dissolution characteristics in Ni60A + 35 wt.% WC composite coatings by LIHRC and the individual laser cladding without preheating. Namely, the completely dissolved WC particles interact with Ni-based alloy solvent to precipitate the blocky and herringbone carbides, while the partially dissolved WC particles still preserve the primary lamellar eutectic structure. A few WC particles are split at the interface of WC and W₂C, and then interact with Ni-based alloy solvent to precipitate the lamellar carbides. Compared with the individual laser cladding without preheating, LIHRC has the relatively lower temperature gradient and the relatively higher laser scanning speed. Therefore, LIHRC can produce the crack-free composite coating with relatively higher microhardness and relatively more homogeneous distribution of WC particles and is successfully applied to strengthen the corrugated roller, showing that LIHRC process has a higher efficiency and good cladding quality.     

Broad-beam laser cladding of Al-Cu alloy coating on AZ91HP magnesium alloy

The resistance to wear and corrosion of AZ91HP Mg alloy was improved by laser cladding Al-Cu alloy. It was found that the clad layer was characterized by AlCu₄ and Mg₁₇Al₁₂ grains embedded in a AlMg matrix. The bonding zone exhibited a white-light planar crystal band with thickness of 10-13 μm. The heat-affected zone formed a eutectic structure due to the Mg diffusion. The microhardness and wear resistance of the coating were improved due to the formation of the hard phases AlCu₄ and Mg₁₇Al₁₂. Owing to the formation of dense Al₂O₃ oxide film, the coating exhibited better corrosion resistance in 3.5 wt.% NaCl solution.     

Laser clad Ni-base alloy added nano- and micron-size CeO2 composites

Micron-size Ni-base alloy (NBA) powders are mixed with both 1.5 wt% (%) micron-CeO₂ (m-CeO₂) and also 1.0–3.0% nano-CeO₂ (n-CeO₂) powders. These mixtures are coated on low carbon steel (Q235) by 2.0 kW CO₂ laser cladding. The effects on microstructures, microhardness and wear resistance of the coating by the addition of m- and n-CeO₂ powders to NBA (m- and n-CeO₂/NBA) have been investigated. Addition to the primary phases of γ-Ni, Cr₂₃C₆ and Ni₃B of NBA coating, CeNi₃ shows up both in m- and n-CeO₂/NBA coatings and CeNi₅ appears only in n-CeO₂/NBA coating. Directional dendrite and coarse equiaxed dendrite are grown in m-CeO₂/NBA coating from interface to central zone, whereas multi-oriented dendrite and fine equiaxed dendrite growth by addition of n-CeO₂. The microhardness and wear resistance of coatings are greatly improved by CeO₂ powder addition, and compared to the addition of 1.0% and 3.0%, 1.5% n-CeO₂/NBA is the best. Hardness and wear resistance of the coating improves with decreasing CeO₂ size from micron to nano.     

Improvement of corrosion resistance of carbon steel using chemical vapor deposition from the mixture of Mo(CO)6 and Cr(CO)6 with an ArF-excimer laser

The corrosion resistance of carbon steel has been improved by the deposition from the mixture of Mo(CO)₆ and Cr(CO)₆ as well as from each carbonyl alone with an ArF-excimer laser (193 nm). The corrosion resistance attained by coating with the films from the mixture is higher than from Mo(CO)₆ alone, while lower than from Cr(CO)₆ alone. While the corrosion resistance increases with beam intensity monotonically over the range 4–25 MW cm^–2 for the deposition from Cr(CO)₆ alone, it tends to decrease slightly above 15 MW cm^–2 for the deposition from Mo(CO)₆ alone and from the mixture. SEM (Scanning Electron Microscope) photographs show that the films from each carbonyl and their mixture consist of small grains that are more densely packed at higher beam intensities. The comparison of the film thickness evaluated from sputtering time to remove the films with that from direct observation with SEM suggests that the density of the film increases with beam intensity. In the films deposited from the mixture, molybdenum is preferentially incorporated from the gas phase. Present name: Department of Quantum Engineering and Systems Science     

Optimization of facet coating for highly strained InGaAs quantum well lasers operating at 1200 nm

The optical output power of a laser diode can be enhanced by anti-reflection (AR) and high-reflection (HR) facet coatings, respectively, at the front and back facet. AR and HR coatings also serve the purpose of protection and passivation of laser diode facets. In this work, we have designed and optimized a single layer λ/4 thick Al₂O₃ film for the AR coating and a stack of λ/4 thick Al₂O₃/λ/4 thick Si bi-layers for the HR coating for highly strained InGaAs quantum-well edge emitting broad area (BA) laser diodes. Effect of the front and back facet reflectivities on output power of the laser diodes has been studied. The light output versus injected current (L–I characteristics) measurements were carried out on selected devices before and after the facet coatings. We have also carried out the numerical simulation and analysis of L–I characteristics for this particular diode structure. The experimental results have been compared and verified with the numerical simulation.     

Influence of treating frequency on microstructure and properties of Al2O3 coating on 304 stainless steel by cathodic plasma electrolytic deposition

Alumina ceramic coatings were fabricated on 304 stainless steel by cathodic plasma electrolytic deposition (CPED). Influence of treating frequency of the power supply on the microstructure and properties of the coatings were studied. The results indicated that coatings obtained at various frequencies on 304 stainless steels were all composed of α-Al₂O₃ and γ-Al₂O₃, and α-Al₂O₃ was the dominant phase. The contents of α-Al₂O₃ decreased gradually in a very small rate with increasing the frequency and γ-Al₂O₃ gradually increased. The surface of alumina ceramic coating was porous. With increasing the frequency, the coating surface gradually became less rough and more compact, resulting in low surface roughness. The bonding strength of Al₂O₃ coating was higher than 22 MPa and was not strongly affected by treating frequency. With increasing the frequency, the alumina coated steels showed better and gradually increasing corrosion resistance than the uncoated one in 3.5% NaCl solution. The coating steel with desirable corrosion resistance was obtained at 800 Hz whose corrosion current potential and corrosion density were −0.237 V and 7.367 × 10⁻⁸ A/cm², respectively.     

Preparation and characterization of the electrodeposited Cr-Al2O3/SiC composite coating

To increase the SiC content in Cr-based coatings, Cr-Al₂O₃/SiC composite coatings were plated in Cr(VI) baths which contained Al₂O₃-coated SiC powders. The Al₂O₃-coated SiC composite particles were synthesized by calcining the precursor prepared by heterogeneous deposition method. The transmission electron microscopy analysis of the particles showed that the nano-SiC particle was packaged by alumina. The zeta potential of the particles collected from the bath was up to +23 mV, a favorable condition for the co-deposition of the particles and chromium. Pulse current was used during the electrodeposition. Scanning Electron Microscopy (SEM) indicated that the coating was compact and combined well with the substrate. Energy dispersive X-ray analysis of Cr-Al₂O₃/SiC coatings demonstrated that the concentration of SiC in the coating reached about 2.5 wt.%. The corrosion behavior of the composite coating was studied by potentiodynamic polarization and electrochemical impedance spectroscopy techniques. The data obtained suggested that the Al₂O₃/SiC particles significantly enhanced the corrosion resistance of the composite coating in 0.05 M HCl solution.     

Phase composition and tribological properties of Ti-Al coatings produced on pure Ti by laser cladding

Ti-Al coatings with ∼14.7, 18.1, 25.2 and 29.7 at.% Al contents were fabricated on pure Ti substrate by laser cladding. The laser cladding Ti-Al coatings were analyzed with X-ray diffraction (XRD), scanning electron microscope (SEM) and X-ray energy dispersive spectroscopy (EDS). It was found that with the increase of Al content, the diffraction peaks shifted gradually to higher 2θ values. The laser cladding Ti-Al coatings with 14.7 and 18.1 at.% Al were composed of α-Ti and α₂-Ti₃Al phases, while those with 25.2 and 29.7 at.% Al were composed of α₂-Ti₃Al phase. With the increase of Al content, the cross-sectional hardness increased, while the fracture toughness decreased. For the laser cladding Ti-Al coatings, when the Al content was ≤18.1 at.%, the wear mechanism was adhesive wear and abrasive wear; while when the Al content ≥25.2 at.%, the wear mechanism was adhesive wear, abrasive wear and microfracture. With the increase of Al content, the wear rate of laser cladding Ti-Al coatings decreased under 1 N normal load, while the wear rate firstly decreased and then increased under a normal load of 3 N. Due to its optimized combination of high hardness and high fracture toughness, the laser cladding Ti-Al coating with 18.1 at.% Al showed the best anti-wear properties at higher normal load.     

Effects of duty ratio at low frequency on growth mechanism of micro-plasma oxidation ceramic coatings on Ti alloy

The aim of this work is to study the effects of duty ratio on the growth mechanism of the ceramic coatings on Ti-6Al-4V alloy prepared by pulsed single-polar MPO at 50 Hz in NaAlO₂ solution. The phase composition of the coatings was studied by X-ray diffraction, and the morphology and the element distribution in the coating were examined through scanning electron microscopy and energy dispersive spectroscopy. The thickness of the coatings was measured by eddy current coating thickness gauge. The corrosion resistance of the coated samples was examined by linear sweep voltammetry technique in 3.5% NaCl solution. The changes of the duty ratio (D) of the anode process led to the changes of the mode of the spark discharge during the pulsed single-polar MPO process, which further influenced the structure and the morphology of the ceramic coatings. The coatings prepared at D = 10% were composed of a large amount of Al₂TiO₅ and a little γ-Al₂O₃ while the coatings prepared at D = 45% were mainly composed of α-Al₂O₃ and γ-Al₂O₃. The coating thickness and the roughness were both increased with the increasing D due to the formation of Al₂O₃. The formation of Al₂TiO₅ resulted from the spark discharge due to the breakdown of the oxide film, while the formation of Al₂O₃ resulted from the spark discharge due to the breakdown of the vapor envelope. The ceramic coatings improved the corrosion resistance of Ti-6Al-4V alloy. And the surface morphology and the coating thickness determined the corrosion resistance of the coated samples prepared at D = 45% was better than that of the coated samples prepared at D = 10%.     

磁场辅助激光熔覆制备Ni60CuMoW复合涂层

采用磁场辅助激光熔覆技术,在Q235钢表面制备了Ni60CuMoW复合涂层,借助SEM,EDS 和XRD 等表征手段对涂层进行了微观组织和物相分析,利用维氏硬度计测试了复合涂层截面的显微硬度分布,通过摩擦磨损实验和电化学测试系统研究了复合涂层的磨损性能和耐腐蚀性能。研究结果表明:涂层主要由-Ni,Cu）固溶体、硅化物和硼化物组成,Cr3Si晶粒细化且均匀致密;磁场辅助作用下,激光熔覆涂层平均显微硬度达到913HV0.5,为无磁场辅助涂层的1.5 倍,磨损失重仅为无磁场涂层的36%,自腐蚀电位上升了100 mV,腐蚀电流密度降低了70%,耐磨耐蚀性能得到了显著改善。     

Zn-ZrO2 nanocomposite coatings: Elecrodeposition and evaluation of corrosion resistance

The Zn and Zn-ZrO₂ composite coatings were produced by electrodeposition technique using sulphate bath. ZrO₂ particles were characterized using scanning electron microscopy (SEM) and X-ray diffraction (XRD). The ZrO₂ particle size distribution in the plating bath and Zeta potential and the ZrO₂ were measured using dynamic light scattering technique (DLS). The corrosion resistance properties of Zn and Zn-ZrO₂ composite coatings were compared by examining the experimental data acquired through polarization, open circuit potential (OCP) and Tafel measurements. The corrosion environment was 3.5 wt% NaCl solution. The variation of amount of ZrO₂ in the solution on their % wt inclusion in the composite and on composite microhardness was investigated. XRD patterns were recorded for Zn and Zn-ZrO₂ coatings to compare their grain size. The SEM images of coatings before and after corrosion under chemical and electrochemical conditions were presented. The results were analyzed to establish the superiority of Zn-ZrO₂ composite over Zn coating.     

Microstructure and wear behavior of γ/Al4C3/TiC/CaF2 composite coating on γ-TiAl intermetallic alloy prepared by Nd:YAG laser cladding

As a further step in obtaining high performance elevated temperature self-lubrication anti-wear composite coatings on TiAl alloy, a novel Ni-P electroless plating method was adopted to encapsulate the as-received CaF₂ in the preparation of precursor NiCr-Cr₃C₂-CaF₂ mixed powders with an aim to decrease its mass loss and increase its compatibility with the metal matrix during a Nd:YAG laser cladding. The microstructure of the coating was examined using X-ray diffraction (XRD), scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS) and the friction and wear behavior of the composite coatings sliding against the hardened 0.45% C steel ring was evaluated using a block-on-ring wear tester at room temperature. It was found that the coating had a unique microstructure consisting of primary dendrites TiC and block Al₄C₃ carbides reinforcement as well as fine isolated spherical CaF₂ solid lubrication particles uniformly dispersed in the NiCrAlTi (γ) matrix. The good friction-reducing and anti-wear abilities of the laser clad composite coating was suggested to the Ni-P electroless plating and the attendant reduction of mass loss of CaF₂ and the increasing of it's wettability with the NiCrAlTi (γ) matrix during the laser cladding process.     

Microstructure and corrosion properties of thick WC composite coating formed by plasma cladding

The thick Ni-coated WC coatings, in a matrix of Nickel-based alloys, were prepared on AISI 1045 steel using plasma cladding equipment. A pre-placed layer of uniform mixture, with different weight fractions of Ni-coated WC powder and Nickel-based alloy powder, on the steel substrate was melted at the high temperature of the plasma jet. The coating composition, microstructure and microhardness were analyzed by X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectrometer (EDS) and microhardness testing. The experimental results show that the metallurgical bond was formed between the coating and substrate. The XRD results show that the coatings contain γ-Ni, carbides (such as M₂₃C₆ and M₇C₃) and boride (such as Fe₂B, Fe₃B phases). SEM shows that all the coatings are crack-free with lower porosity (<1%). It is found that the microhardness and the electrochemical behavior of the coatings are depended on the content of Ni-coated WC powder. The corrosion mechanism for the coatings may be due to the microgalvance corrosion between the phases in the cladding coatings.     

激光熔覆FeCrNiMnMoxB0.5高熵合金涂层组织与耐蚀性能

为了获得性能优异的涂层材料,采用激光熔覆的方法在Q235钢基体上制备了不同Mo含量的FeCrNiMnMoB0.5系高熵合金涂层,着重探究Mo对高熵合金组织与性能的影响。通过金相、X射线衍射、扫描电镜、硬度计、电化学工作站分别研究了高熵合金涂层的显微组织、相结构、显微硬度及耐蚀性能。结果表明:FeCrNiMnMoB0.5系高熵合金组织为树枝晶,主要由fcc相和少量金属间化合物构成。当添加少量Mo时,涂层的硬度较低,为290 HV,随着Mo的增加,晶格畸变加剧,出现少量金属化合物,涂层硬度最大增加到658 HV。在模拟饱和盐水泥浆溶液中FeCrNiMnMo0.4B0.5表现出较好的耐腐蚀性。     

Electrolytical production of Ni + Mo + Si composite coatings with enhanced content of Si

Ni + Mo + Si composite coatings were prepared by co-deposition of nickel with molybdenum and silicon powders from a nickel solution in which Mo and Si particles were suspended by stirring. The layers have been deposited on a carbon steel substrate (St3S) under galvanostatic conditions. The content of Si in deposited layers was about 2-5 wt.% depending on deposition current density and the value of electric charge. For comparison Ni + Mo composite coatings were obtained under analogous current conditions. Composite coatings of enhanced Si content (15 wt.%) were deposited from an electrolyte in which 40 g/dm³ of Si covered with electroless plated nickel was dispersed. Deposition current density was equal 0.1 A/cm² and the value of electric charge Q = 500 C/cm². The thickness of the coatings was about 100-300 μm depending on their kind, electric charge and the deposition current density. Surface and cross-section morphology were investigated by scanning electron microscope (SEM). All deposited coatings are characterized by great, developed surface area. No internal stresses causing their cracking were observed. Chemical composition of the layers was determined by X-ray fluorescence spectroscopy (XRF) method and quantitative X-ray analysis (QXRD). It was stated, that the content of molybdenum and silicon in Ni + Mo + Si coatings depends on deposition current density and the amount of the powder in bath. The results of structural investigation of the obtained layers by the X-ray diffraction (XRD) method show, that they consist in crystalline Mo or Mo and Si phases built into Ni matrix. Moreover, Ni + Mo + Si composite coatings were modified by thermal treatment. It has been found that the thermal treatment of Ni + Mo + Si composite coatings caused that the new phases (NiSi, Mo₂Ni₃Si and Ni₆Mo₆C_1.06) were obtained.     

Synergistic effect of ultrasonic cavitation erosion and corrosion of WC–CoCr and FeCrSiBMn coatings prepared by HVOF spraying

The high-velocity oxygen-fuel (HVOF) spraying process was used to fabricate conventional WC–10Co–4Cr coatings and FeCrSiBMn amorphous/nanocrystalline coatings. The synergistic effect of cavitation erosion and corrosion of both coatings was investigated. The results showed that the WC–10Co–4Cr coating had better cavitation erosion–corrosion resistance than the FeCrSiBMn coating in 3.5 wt.% NaCl solution. After eroded for 30 h, the volume loss rate of the WC–10Co–4Cr coating was about 2/5 that of the FeCrSiBMn coating. In the total cumulative volume loss rate under cavitation erosion–corrosion condition, the pure cavitation erosion played a key role for both coatings, and the total contribution of pure corrosion and erosion-induced corrosion of the WC–10Co–4Cr coating was larger than that of the FeCrSiBMn coating. Mechanical effect was the main factor for cavitation erosion–corrosion behavior of both coatings.     

Process and performance of hot dip zinc coatings containing ZnO and Ni-P under layers as barrier protection

A new coating system of under layer for hot dip zinc coating was explored as an effective coating for steel especially for application in relatively high aggressive environments. The influence of different barrier layers formed prior to hot dip galvanization was investigated to optimize high performance protective galvanic coatings. The deposition of ZnO and Ni-P inner layers and characteristics of hotdip zinc coatings were explored in this study. The coating morphology was characterized by scanning electron microscope (SEM) analysis. The hot dip zinc coatings containing under layer showed substantial improvement in their properties such as good adhesion, and high hardness. In addition, a decrease in the thickness of the coating layer and an enhancement of the corrosion resistance were found. Open circuit potential (OCP) of different galvanized layers in different corrosive media viz. 5% NaCl and 0.5 M H₂SO₄ solutions at 25 ± 1 °C was measured as a function of time. A nobler OCP was exhibited for samples treated with ZnO and Ni than sample of pure Zn; this indicates a dissolution process followed by passivation due to the surface oxide formation. The high negative OCP can be attributed to the better alloying reaction between Zn and Fe and to the sacrificial nature of the top pure zinc layer.     

Laser surface alloying of an electroless Ni–P coating with Al-356 substrate

Laser surface alloying of an electroless plating Ni–P coatings on an Al-356 aluminium alloy was carried out using a 1-kW pulsed Nd:YAG laser. The microstructure, chemical composition and phase identification of the alloyed layer were determined using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX) and X-ray diffractometry (XRD), respectively. It was shown that laser surface treatment produced a relatively smooth, crack-free and hard surface layer. The hardness of the surface significantly increased due to the formation of the uniformly distributed fine Ni–Al intermetallic phases. The corrosion behaviour of the surface alloyed specimens in 3.5% NaCl solution at 23 °C was also determined by electrochemical techniques. The laser-alloyed surface showed an improved corrosion and pitting potential compared to the substrate as well as the plated Ni–P coating.