Effect of WC-17Co content on microstructure, mechanical properties and wear resistance of WC-17Co/Ni composites produced with cold spraying

Aluminum alloys face increased performance demands when exposed to harsh environments, which requires enhanced surface protection and damage repair to such components. This study examines the fabrication of high-performance WC-17Co/Ni composite coatings on AA2024 alloy substrate using cold spraying and elucidates the influence of WC-17Co content on microstructures, mechanical properties, and wear resistance. The fatigue life and fracture mechanism of coatings under various loadings were subjected to analysis. The study demonstrates that an increase in the hardness of the composite coating is significantly associated with the addition of hard phase, while the bonding strength remains unaffected. The steady-state friction coefficient of the coating goes through a maximum, and the wear mechanism is characterized by fatigue wear and abrasive wear. The composite coating exhibits excellent corrosion resistance. The increased hard phase WC-17Co content (63.5 %) in the coating and the increased hardness (434.7 HV_0.3) of the coating allow it to withstand large loads, and reduce the impact of fatigue cycle loads on the coating, thereby improving its fatigue resistance. This study offers valuable theoretical guidance for enhancing the performance and extending the service life of aluminum alloys in harsh environments. It holds significant engineering application value within the field of surface engineering.