Synergistic enhancement of mechanical, tribological and electrochemical properties in thermally sprayed Al-WC & Al–Al2O3 composite coatings

The expansion of blue economy driven by exploration of eco-friendly marine resources including mining and transportation is a pivotal driver for global economic growth. However, the constraint of limited-service life of engineering equipment operating in marine environment persists due to wear and chloride induced corrosion threatening its structural integrity. To address these challenges, this study developed aluminum-based metal matrix composite (AMMC) coatings reinforced with ceramic (Al 2 O 3 ) and cermet (WC–12Co) constituents with varying compositions on AA-6061 substrates. The coatings were deposited via Atmospheric Plasma Spray (APS) to evaluate their efficacy for improving mechanical, tribological and electrochemical properties of the base substrate. Results of microstructural characterizations and electrochemical testing demonstrate an active dissolution in the bare substrate and aluminum coatings unlike composite coatings. Explicitly the composite 10WC exhibited an optimal performance tradeoff, yielding 40.66% increase in microhardness, and low mean specific wear rate. Furthermore, the 10WC achieved dense microstructure with uniform surface, and substantial reduction in corrosion rate 0.5622mpy as compared to the bare substrate 427.81mpy. Consequently, the application of AMMC via APS can offer a desired robust and ecofriendly strategy for enhancing the operational lifespan of marine assets.