Improving the mechanical properties of metal matrix composites (MMCs) by the addition of a ceramic phase is one of the present studying hot spots. Understanding the morphology evolution rule of the ceramic phase during laser cladding is a critical issue to its wider industrial applications. In the present paper, different CeO2 contents with WC reinforced Ni matrix composite coatings were prepared by laser in-situ synthesis technology. The influence of CeO2 content on the WC morphology and the attendant mechanical properties was investigated by using scanning electron microscopy (SEM), X-ray diffraction (XRD), energy disperse X-ray (EDX) spectroscopy, hardmeter and frictional tester. The result shows that the shape of WC particles has a close relation to the addition of rare earth oxide CeO2. Specifically, at first, with the increasing CeO2 additions, the aspect ratio of WC particles reaches the minimum value when 2 wt. % CeO2 is added. Then, the aspect ratio increases with further increasing CeO2 additions. In addition, the effect of CeO2 on macroscopic morphology of laser cladding coating and the mechanism of CeO2 on the morphology evolution of WC particle were investigated. Finally, microhardness and wear results show that the coating with 2 wt. % CeO2 has the best mechanical properties.

Influence of CeO2 content on WC morphology and mechanical properties of WC/Ni matrix composites coating prepared by laser in-situ synthesis method

Research Progress in Surface Strengthening Technology of Carbide-based Coating

Ceramic/metal composites have been widely studied and applied because of their many advantageous properties. However, limited work on the additive manufacturing (AM) of ceramic controllably reinforced metal matrix composites (MMCs) has been conducted. To customize the compositions and properties at user-defined positions within a single MMC component, we developed a low-cost method, wire–powder–arc additive manufacturing (WPA-AM), for the rapid fabrication of ceramic particles to selectively reinforce aluminum matrix composite (AMC) structures. Multi-material AMC components with the controllable addition of various carbide ceramic particles (B4C, SiC, TiC, and WC/W2C) have been successfully fabricated via the WPA-AM system. We investigated the effects of the four kinds of ceramic particles on the arc behaviors, the droplet transfer modes in the WPA-AM process, and the forming qualities of the deposited AMC layers. The particle distribution, microstructures, and interfacial characteristics of the AMC structures have been studied. Furthermore, the mechanical properties of the single-AMC and the cyclic laminated multi-AMC structures were comparatively analyzed. This work verified the feasibility of manufacturing ceramic/metal multi-material structures by the WPA-AM process, which will promote the development and application of AM technology. 

Wire–powder–arc additive manufacturing: A viable strategy to fabricate carbide ceramic/aluminum alloy multi-material structures

In this study, the Ni-based WC reinforced MMC coating was conducted by a novel process called induction cladding (IC). Powder mixtures of NiCrBSi and NiCrBSi-WC were pre-located on an AISI 316 stainless steel chamber and heated at 1200 °C for 20 min with a high frequency induction coil in an Ar atmosphere and cooled in the same environment. The coating layer showed an intense and non-porous metallurgical bond to the stainless steel. As a result of the microstructural and phase analysis of the coating layer, γ‑nickel main phases with Ni3B, Ni3Fe, Ni3Si, Cr23C6, CrB and Cr7C3 were determined in dendritic and cellular regions. In addition, WC and W2C phases were observed in reinforced samples. The average hardness value of the IC clad coating was 2.8 times higher, compared to AISI 316, due to the formation of hard carbide and boride phases in the interdendritic regions. The COF values and wear rate of the cladded samples were decreased compared to the AISI 316. Increasing the amount of WC reinforced powder used in the IC process increased the wear resistance by up to 10 times to be compared with the stainless steel AISI 316.

Microstructural and tribological properties of induction cladded NiCrBSi /WC composite coatings

Damage evolution and plastic deformation mechanism of passivation layer during shear rheological polishing of polycrystalline tungsten

This paper presents a new type of FeNi matrix composite coating reinforced with multi-scale carbides WC-TiC fabricated by in-situ synthesis method PTAMR (plasma transferred arc metallurgical reaction). The microstructures, phases, hardness, and tribology properties of the composite coating were analyzed. Results show that the multi-scale carbides WC-TiC with fine intact shape were successfully in-situ synthesized in the matrix. Owing to the in-situ synthesis method, plenty of TiC tiny carbides in-situ grow in both the carbide WC and matrix, known as the precipitation hardening, by which the hardness of carbide WC and matrix are increased from 1497 to 1682 HV4.9 and 411 to 731 HV4.9 respectively. The analysis of crystallographic relationship shows that the lattice misfit between 10 1 ¯ 0 WC and (001)TiC is 6.26%, indicating carbides WC and TiC can act as mutual effective heterogeneous nuclei and promote each other. Benefit from the in-situ WC-TiC multi-scale carbides hybrid growth characteristic, the wear resistance, and frictional stability are all increased in compared with the coating reinforced with in-situ single-carbide WC.

Improving wear resistance and friction stability of FeNi matrix coating by in-situ multi-carbide WC-TiC via PTA metallurgical reaction

The effects of Ti addition on the microstructure and tribological properties of in situ composite carbide WC-TiC/FeNi coating were studied using XRD, SEM, EDS, and friction and dry sliding wear tests. The results show that the composite carbide WC-TiC was successfully in situ synthesized in the coating, and with Ti addition increased by 0.1 from 0.1 to 0.4 wt.%, the in situ carbide TiC increased from 3.4 to 24.4 vol.%, while the carbide WC decreased from 32.5 to 24.2 vol.%, and the coating hardness increased from 1027 to 1196 HV4.9. The friction and dry sliding wear tests show that for WC-TiC/FeNi composite coating, the addition of Ti can not only reduce the friction coefficient, the mass loss of both the coatings and its counterpart but also improve the friction stability, service life, and wear rate (WR). The relationship between the Ti addition and the coating wear rate fits the exponential decay equation WR = 10.6 − 0.089 $$\times$$
 e (Ti/0.098). The main wear mechanisms of in situ WC-TiC/FeNi composite carbide coating are abrasive wear, oxidative wear, and micro-plow wear.

Effects of Ti Addition on Microstructure and Tribological Properties of In Situ Composite Carbide Coating WC-TiC/FeNi Fabricated by Plasma Transferred Arc Metallurgical Reaction

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Improving wear resistance and friction stability of FeNi matrix coating by in-situ multi-carbide WC-TiC via PTA metallurgical reaction

Effects of Ti Addition on Microstructure and Tribological Properties of In Situ Composite Carbide Coating WC-TiC/FeNi Fabricated by Plasma Transferred Arc Metallurgical Reaction