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<p>Plasma-sprayed metal-ceramic composite coatings are widely applied due to their superior properties. However, considering the multi-physics interactions during high-velocity impacts, the composite particles deposition behavior remains poorly understood. This study systematically investigates the microstructure evolution of NiCrMoNb-Al<sub>2</sub>O<sub>3</sub> coatings deposited on 10CrNi3MoV substrates using a wide-velocity range high-energy plasma spraying (WPS) process. A three-dimensional coupled Eulerian-Lagrangian (CEL) multi-particle model was developed and validated to elucidate the evolution of stress, strain, and temperature fields during the co-deposition of NiCrMoNb and Al<sub>2</sub>O<sub>3</sub> particles. The relationship between particles velocity and Al<sub>2</sub>O<sub>3</sub> deposition efficiency was discussed. The coating displayed characteristic stress-strain distributions, where substrate deformation was dominated by compression in the impact zone and tension in the periphery region. Both simulations and experiments confirmed that the coating microstructure strongly depended on particle velocity. An increase of 50&#xa0;m/s led to a 27% reduction in Al<sub>2</sub>O<sub>3</sub> content and 17% decrease in coating porosity. This work provides fundamental insights for optimizing the performance of NiCrMoNb-Al<sub>2</sub>O<sub>3</sub> composite coatings.</p>

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Development and Modeling of Co-deposition Process for NiCrMoNb-Al2O3 Metal-Ceramic Composite Coatings by Plasma Spraying

  • 期刊论文

  • 发表日期：

    2026年4月24日

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  • F. Zhang,
  • T. B. Zhang,
  • Y. Wang,
  • Y. Bai,
  • Y. F. Liu,
  • M. Liu,
  • G. Z. Ma,
  • H. D. Wang

摘要

Plasma-sprayed metal-ceramic composite coatings are widely applied due to their superior properties. However, considering the multi-physics interactions during high-velocity impacts, the composite particles deposition behavior remains poorly understood. This study systematically investigates the microstructure evolution of NiCrMoNb-Al2O3 coatings deposited on 10CrNi3MoV substrates using a wide-velocity range high-energy plasma spraying (WPS) process. A three-dimensional coupled Eulerian-Lagrangian (CEL) multi-particle model was developed and validated to elucidate the evolution of stress, strain, and temperature fields during the co-deposition of NiCrMoNb and Al2O3 particles. The relationship between particles velocity and Al2O3 deposition efficiency was discussed. The coating displayed characteristic stress-strain distributions, where substrate deformation was dominated by compression in the impact zone and tension in the periphery region. Both simulations and experiments confirmed that the coating microstructure strongly depended on particle velocity. An increase of 50 m/s led to a 27% reduction in Al2O3 content and 17% decrease in coating porosity. This work provides fundamental insights for optimizing the performance of NiCrMoNb-Al2O3 composite coatings.