Amorphous Thermal Spray Coating with Hard Materials Exhibiting Cleavage Fracture

Hard materials were mixed with alloy powders and thermally sprayed at an ultra rapid cooling rate of more than 106°C/s. For example, 65Ni15Cr16P4B at% alloy powder containing tungsten carbide was thermally sprayed. SEM image showed tungsten carbide paticles were scattered in the amorphous alloy coatings. The resulting thermal coatings showed low friction and high wear resistance in a reciprocating-slide-type friction-testing machine because tungsten carbides exhibited cleavage fracture. The stress analysis of an amorphous alloy coating with low friction was also carried out by the finite element method.