Microstructure, residual stress and mechanical properties of double carbides cermet coatings manufactured on AZ31 substrate by high velocity oxy-fuel spraying

The study investigated the microstructures, residual stress and mechanical properties of double carbides cermet coatings manufactured on AZ31 magnesium alloy substrate by high-velocity oxy-fuel spraying (HVOF). The HVOF spraying was carried out using a JP 5000 TAFA spray system and the commercially available powder WC-20Cr3C2-7Ni was used to manufacture coatings. The variable process parameter was spray distance (320, 360 and 400 mm). The top surfaces of the manufactured coatings are typical for HVOF coatings and is relatively smooth. Nevertheless, some irregularities and voids are observed. All coatings exhibit dense structure with relatively low porosity level (below 3 vol. %) as well as a robust mechanical binding to the substrate which indicates high adhesion. More deep microstructure analysis carried out by TEM microscopy revealed two types of precipitation: WC hexagonal phase in the space group P-6m2 with irregular shape and size as well as Cr7C3 orthorhombic one, in the space group P nma with a rounded shape and regular size. Phase composition after the spraying process indicates the hexagonal WC phase as the main one. Additionally, two chromium carbides phases, Cr3C2 and Cr3C7 have been identified. A small peak of hexagonal W2C carbide was found as well. Analysis of residual stress showed that both components of linear stress for all deposited coatings have a compressive nature. The increasing spray distance caused an increase of the linear stress values, from - 72.7 up to - 131.5 MPa for delta 11 and from - 57.2 up to - 112.2 MPa for delta 22. Such values could suggest that thermal stress generated during coating deposition was also low. In the case of the shear stress the values are much lower than linear one, but with the same tendency, increasing with longer spray distance: 14.2, 21.0 and 32.2 MPa for 320, 360 and 400 mm, respectively. The obtained results of HIT show a slight influence on the spray distance. With the increasing spraying distance, the value of hardness decreasing: 12.96, 12.53 and 11.76 GPa according to SD equal to 320, 360 and 400 mm, respectively. Similar was in the case of the EIT values: 315, 309 and 304 GPa for 320, 360 and 400 mm, respectively. All values of the fracture toughness were in the range between 3.5 and 4.0 MPa m1/2, with little influece of the spray distance.