Advanced deposition characteristics of kinetic sprayed bronze/diamond composite by tailoring feedstock properties

In this study, the effect of protective nickel film on diamond particles was studied with the goal of preventing fracture and obtaining a uniform diamond distribution in a bronze/diamond composite coating during kinetic spraying. Two types of bronze/diamond composite were deposited on aluminum substrate. For comparison with experimental results, the impact behavior between diamonds in the gas flow field was simulated by finite element analysis (using ABAQUS/Explicit 6.7-2). Size distribution and deposition efficiency of the diamond particles in the composite coatings were analyzed through scanning electron microscopy and image analysis methods. Diamond fracturing was avoided because the impact energy was mostly absorbed by the outer protective nickel film on the diamond particle during impact. The uniform distribution and deposition efficiency of diamond particles in the coating layer could also be achieved by tailoring the physical properties (density, size, etc.) of the feedstock. (C) 2008 Elsevier Ltd. All rights reserved.