journal article·2025-09Open access

Influence of inter-splat adheres on properties of HVOF-sprayed 434 stainless steel coatings on T6061 aluminum alloy

Yaming Li, Haimin Zhai, Wensheng Li, Ting Zhang, Xinjian Zhang

Abstract

Bonding and adhesion are crucial factors determining the properties during HOVF-spraying. 434 stainless steel coatings have been applied T6061 alloy substrate using High-Velocity Oxygen Fuel (HVOF) with different spray parameters.The inter-splat adhesion of stainless steel (SS) coatings was investigated through shearing method,transmission electron microscope(TEM). The relationship between the inter-splat adheres and properties of the bonding strength, corrosion and wear resistance of SS coatings was revealed.Results showed that for thicker coatings containing more layers, the deposition temperature was higher, the coating porosity was lower, and the adhesion between splats was stronger,presented better properties. The optimum SS1-3 coated sample showed a maximum bonding strength of 52.9 MPa, a wear rate is only half of that of the SS 2-2,reach 5.94×10 -5 mm 3 /(N·m),all because of the localised metallurgical bonding at the splat interface.Compared to pure T6061 aluminium, its presented better corrosion resistance,and the corrosion current density is reduced from 18.6 μA/cm 2 to 3.5 μA/cm 2 . Finally, mechanisms for coating failure were established to explain the effects of inter-splat adhesion on the SS coatings under tension and wear.
Source: openalex_inverted_index · Quality: baseline

Research context

OpenAlex topics: High-Temperature Coating Behaviors · Materials Engineering and Processing · Material Properties and Applications

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (38)

Show source-provided references
1. In-situ investigation of helium effect on diverse precipitate/matrix interface areas in irradiated 5052 aluminum alloy
2. Mechanical performance of zirconia-silica bilayer coating on aluminum alloys with varying porosities: deep learning and microstructure-based FEM
3. Review of recent trends and developments in aluminium 7075 alloy and its metal matrix composites (MMCs) for aircraft applications10.1016/j.rineng.2023.101372 ↗
4. Corrosion inhibition performance of RNC-n on aluminum alloy surface in alkaline solution
5. Advances in functionalized polymer coatings on biodegradable magnesium alloys – a review10.1016/j.actbio.2018.08.030 ↗
6. Influence of high power impulse magnetron sputtering pulse parameters on the properties of aluminum nitride coatings10.1016/j.surfcoat.2014.05.028 ↗
7. Investigation of the microstructure, growth mechanism, and corrosion behavior of a new Zr–Ti conversion coating on 6016 aluminum alloy10.1016/j.jmrt.2024.05.138 ↗
8. Characterization and mechanical properties of stainless steel coatings deposited by HVOF on ZE41 magnesium alloy10.1016/j.surfcoat.2018.12.056 ↗
9. Corrosion behavior of HVOF sprayed 304 stainless steel coating on 6061 substrate in 3.5 wt% NaCl solution
10. Development of particle interface bonding in thermal spray coatings: a review
11. Effect of temperature and zinc coating on interfacial bonding between steel and aluminum dissimilar material10.1016/j.promfg.2019.12.047 ↗
12. Promoting bonding strength between internal Al-Si based gradient coating and aluminum alloy cylinder bore by forming homo-epitaxial growth interface10.1016/j.matdes.2023.111764 ↗
13. Fabrication and characterization of TiB2-TiC-Co wear-resistant coatings on AZ91D magnesium alloy10.1016/j.surfcoat.2019.02.090 ↗
14. Deposition mechanism and fracture characterization of 434 stainless steel HOVF coating on T6061 aluminum alloy10.1016/j.jmrt.2024.08.163 ↗
15. Temperature curve, microstructure evolution, and interface bonding of plasma sprayed nickel-based coating under plasma arc/high-frequency induction remelting
16. Deposition, microstructure and hardness of AlCoCrFeNi2.1 eutectic high entropy alloy coatings by cold spray, HVOF, and plasma spray
17. Enhancing comprehensive properties of HVOF thermally sprayed WC-10Co coatings using two grain inhibitors10.1016/j.surfcoat.2023.130323 ↗
18. Evaluation of hydrogen permeation through standalone thermally sprayed coatings of AISI 316L stainless steel10.1016/j.ijhydene.2018.01.021 ↗
19. Dual-scale oxide dispersoids reinforcement of Fe–40 at.%Al intermetallic coating for both high hardness and high fracture toughness10.1016/j.msea.2012.06.037 ↗
20. The influence of HVOF spraying parameters on the microstructure, residual stress and cavitation resistance of FeMnCrSi coatings10.1016/j.surfcoat.2017.07.073 ↗
21. Improving bond strength and deposition efficiency of ceramic coatings via low pressure cold spraying: a study on hydroxyapatite coatings with Cu-Zn blends
22. Residual stress development in cold sprayed Al, Cu and Ti coatings10.1016/j.actamat.2013.06.033 ↗
23. Conditions and mechanisms for the bonding of a molten ceramic droplet to a substrate after high-speed impact10.1016/j.actamat.2016.07.057 ↗
24. Interfacial bonding mechanism and properties of HVOF-sprayed Fe-based amorphous coatings on LA141 magnesium alloy substrate10.1016/j.surfcoat.2021.127801 ↗
25. Synergistic interplay between residual stress, hardness, and microstructural evolution in laser peened stainless steel 347
26. Deposition mechanism and fracture characterization of 434 stainless steel HOVF coating on T6061 aluminum alloy10.1016/j.jmrt.2024.08.163 ↗
27. Characterisation of three dimensional porosity in an Fe-based amorphous coating and its correlation with corrosion behaviour10.1016/j.corsci.2015.01.022 ↗
28. Effect of different overlap cladding transition layer – austenitic stainless steel coating and defect degree on corrosion resistance10.1016/j.corsci.2024.112222 ↗
29. Protective properties of inhibitor- containing composite coatings on a Mg alloy10.1016/j.corsci.2015.10.026 ↗
30. Improving wear and corrosion resistance of HVAF sprayed 316L stainless steel coating by adding TiB2 ceramic particles and CeO210.1016/j.jmrt.2024.06.146 ↗
31. Corrosion resistance mechanisms of detonation sprayed Fe-based amorphous coating on AZ31B magnesium alloy10.1016/j.jnoncrysol.2021.121276 ↗
32. Influence of deposition temperature on the splat bonding and mechanical properties of plasma-sprayed tungsten coatings
33. Fabrication and properties of thermal sprayed stainless steel-based nanocomposite coatings10.1016/j.surfcoat.2015.04.018 ↗
34. Dynamic recrystallization behavior and interfacial bonding mechanism of 14Cr ferrite steel during hot deformation bonding10.1016/j.jmst.2020.01.010 ↗
35. Coating failure detection in scratch testing: a cross-sectional SEM/FIB microscopic study coupled with nonlinear analysis methods in a model titanium nitride/stainless steel system
36. Surface oxide and hydroxide effects on aluminum microparticle impact bonding10.1016/j.actamat.2020.07.011 ↗
37. Study on interface bonding mechanisms for high-velocity oxygen-fuel spraying of WC-12Co coatings on AZ31B magnesium alloy10.1016/j.jmrt.2024.10.243 ↗
38. Interface bonding between particle and substrate during HVOF spraying10.1016/j.apsusc.2014.08.196 ↗