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Comparative Study on the Cavitation Erosion and Sliding Wear of Cold-Sprayed Al/Al2O3 and Cu/Al2O3 Coatings, and Stainless Steel, Aluminium Alloy, Copper and Brass

1
Department of Materials Engineering, Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka 36D, Lublin 20-618, Poland
2
Faculty of Mechanical Engineering, Wrocław University of Science and Technology, 5 Łukasiewicza Street, Wrocław 50371, Poland
*
Authors to whom correspondence should be addressed.
Metals 2020, 10(7), 856; https://doi.org/10.3390/met10070856
Received: 30 May 2020 / Revised: 18 June 2020 / Accepted: 22 June 2020 / Published: 28 June 2020
The paper investigates the cavitation erosion (CE) and sliding wear (SW) resistance of cold-sprayed Al/Al2O3 and Cu/Al2O3 composites and studies them in relation to a set of metallic materials such as aluminium alloy (AlCu4Mg1), pure copper (Cu110), brass (CuZn40Pb2) and stainless steel (AISI 304). The coatings were deposited on stainless steel by low-pressure cold spray (LPCS) using Al (40 wt.%) and Cu (50 wt.%) blended with Al2O3 (60 and 50 wt.%, respectively) feedstocks. CE resistance was estimated by the stationary sample method according to the ASTM G32 standard. The SW test was conducted using a ball-on-disc tester with compliance to the ASTM G99 standard. Results obtained for the LPCS coatings show that the Cu/Al2O3 coating exhibits a denser structure but lower adhesion and microhardness than Al/Al2O3. The Al/Al2O3 and Cu/Al2O3 resistance to cavitation is lower than for bulk alloys; however, composites present higher sliding wear resistance to that of AlCu4Mg1, CuZn40Pb2 and stainless steel. The CE wear mechanisms of LPCS composites start at the structural discontinuities and non-uniformities. The cavitation erosion degradation mechanism of Al/Al2O3 relies on chunk material detachment while that of Cu/Al2O3 initiates by alumina removal and continues as layer-like Cu-metallic material removal. CE damage of metal alloys relies on the fatigue-induced removal of deformed material. The SW mechanism of bulk alloys has a dominant adhesive mode. The addition of Al2O3 successfully reduces the material loss of LPCS composites but increases the friction coefficient. Coatings’ wear mechanism has an adhesive-abrasive mode. In both CE and SW environment, the behaviour of the cold-sprayed Cu/Al2O3 composite is much more promising than that of the Al/Al2O3. View Full-Text
Keywords: cavitation erosion; sliding; wear; friction coefficient; failure mechanism; cold spray; composite; copper; aluminium; alumina; MMC cavitation erosion; sliding; wear; friction coefficient; failure mechanism; cold spray; composite; copper; aluminium; alumina; MMC
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MDPI and ACS Style

Szala, M.; Łatka, L.; Walczak, M.; Winnicki, M. Comparative Study on the Cavitation Erosion and Sliding Wear of Cold-Sprayed Al/Al2O3 and Cu/Al2O3 Coatings, and Stainless Steel, Aluminium Alloy, Copper and Brass. Metals 2020, 10, 856.

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