LPCS Ni-Zn-Al2O3 Intermediate Layer Enhanced SPS NiCr-Cr3C2 Coating with Higher Corrosion and Wear Resistances.

The double-layer NiCr-Cr₃C₂/Ni-Zn-Al₂O₃ coatings with sufficient corrosion and wear resistance were prepared on low carbon steel substrates. The intermediate layers Ni-Zn-Al₂O₃ were fabricated by using low-pressure cold spray (LPCS) method to improve the salt fog corrosion resistance properties of the supersonic plasma spray (SPS) NiCr-Cr₃C₂ coatings. The friction and wear performance for the double-layer and single-layer NiCr-Cr₃C₂ coatings were carried out by line-contact reciprocating sliding, respectively. Combined with the coating surface analysis techniques, the effect of the salt fog corrosion on the tribological properties of the double-layer coatings was studied. The results showed that the double-layer coatings exhibited better wear resistance than that of the single-layer coatings, due to the better corrosion resistance of the intermediate layer; the wear mass losses of the double-layer coatings was reduced by 70% than that of the single layer coatings and the wear mechanism of coatings after salt fog corrosion conditions is mainly corrosion wear. [ABSTRACT FROM AUTHOR]