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<p>To improve the bonding strength at the coating/substrate interface and increase the proportion of interfacial metallurgical bonding, plasma spray melting (PSM) technology for coating preparation was proposed. The coatings were prepared using PSM and air plasma spray (APS) on Q235 steel substrates in this paper, respectively. The micro-morphology of the coatings and the morphology of the molten droplet splat and melt pool were characterized by scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDS). The mechanical properties of the coatings were also investigated, including bond strength, microhardness, nanoindentation, and residual stress. The coating/substrate metallurgical bonding was analyzed by electron backscatter diffraction (EBSD) and micro-zone x-ray diffraction (XRD). The results showed that the plasma-sprayed coating exhibited distinct continuous metallurgical bonding characteristics with the substrate, and the elemental diffusion depth was approximately 4&#xa0;μm. Compared to the APS coating, the porosity was reduced to 2.3%. The interfacial region was metallurgically bonded, and the internal bonding strength of the coating reached 53&#xa0;MPa. Additionally, the coating was less prone to cracking due to the favorable elastic modulus matching between the coating and the substrate.</p>

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Study of the Mechanical Properties and Metallurgical Behavior of Nickel-Based Coatings: Atmospheric Plasma Spraying and Plasma Spray Melting

  • 期刊论文

  • 发表日期：

    2025年6月30日

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  • Yuheng Li,
  • Baodan Zhang,
  • Ming Liu,
  • Yuncai Zhao,
  • Song Xiao,
  • Rui Gao,
  • Jie Zhang,
  • Haidou Wang

摘要

To improve the bonding strength at the coating/substrate interface and increase the proportion of interfacial metallurgical bonding, plasma spray melting (PSM) technology for coating preparation was proposed. The coatings were prepared using PSM and air plasma spray (APS) on Q235 steel substrates in this paper, respectively. The micro-morphology of the coatings and the morphology of the molten droplet splat and melt pool were characterized by scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDS). The mechanical properties of the coatings were also investigated, including bond strength, microhardness, nanoindentation, and residual stress. The coating/substrate metallurgical bonding was analyzed by electron backscatter diffraction (EBSD) and micro-zone x-ray diffraction (XRD). The results showed that the plasma-sprayed coating exhibited distinct continuous metallurgical bonding characteristics with the substrate, and the elemental diffusion depth was approximately 4 μm. Compared to the APS coating, the porosity was reduced to 2.3%. The interfacial region was metallurgically bonded, and the internal bonding strength of the coating reached 53 MPa. Additionally, the coating was less prone to cracking due to the favorable elastic modulus matching between the coating and the substrate.