Adapting high-speed indentation mapping for investigating microstructure-property correlations in chromium carbide-nickel alloy coatings: Challenges and solutions

This study investigates the microstructural and mechanical characteristics of chromium carbide‑nickel rich alloy coatings produced through laser cladding, detonation spraying, and plasma spraying techniques. While all three processing techniques used the same feedstock powder, each method yields coatings with unique microstructures encompassing varying compositions and length scales. Employing Field Emission Scanning Electron Microscopy (FE-SEM) in combination with Energy Dispersive Spectroscopy (EDS) and nanoindentation mapping, local microstructure and mechanical properties were assessed at the micrometre length scale. Laser-clad coatings exhibit a typical metal matrix composite microstructure with high carbide content, distinct (MoNb)C2 phases, and Fe in the metallic matrix, while the thermal sprayed coatings showed carbides of varying sizes and metallic matrix with varying degrees of chromium dissolved in it. The instrumented indentation technique helped precisely record the microstructural features in all the coatings. Chromium carbide consistently emerges as the hardest phase across all coatings, with variations in metallic matrix hardness. Higher matrix hardness in thermal sprayed coatings correlates with increased Cr content, attributed to extended solid solubility of Cr and the presence of Mo and Nb. Energy dispersive spectroscopy and transmission electron microscopy provided clearer insight into the microstructure. This study highlights a direct one-to-one correlation between microstructure and mechanical properties mapped using instrumented indentation techniques in chromium carbide‑nickel rich coatings across different deposition methods. [Display omitted] •One-to-one correlation between microstructure and mechanical properties via nanoindentation, microscopy and EDS.•Microstructure variations between laser cladding and thermal spraying observed, process dependence.•Laser cladding yields highest carbide content and a typical metal matrix composite microstructure.•Hardness of chromium carbide remains consistent across coatings, while Cr controls metallic matrix hardness.•Insights on microstructural and mechanical properties can significantly aidcoating optimisation for diverse applications.