Fatigue Bending of V-Notched Cold-Sprayed FeCoCrNiMn Coatings

Abstract

Cold-spray coatings were produced by FeCoCrNiMn high-entropy alloy powders deposited on carbon steel substrate. The coatings were realized at intermediate temperature and high pressure (at 1100 °C and 7 MPa). The coating microstructure was characterized by scanning electron microscopy and X-ray diffraction, revealing a very dense deposition and high flattening ratio of the splatted particles. This had a large influence on the strong adhesion of the coating to the substrate. The hardness and residual stress profiles were measured through nanoindentation and X-ray diffraction from the peak broadening measured layer by layer. The cyclic behavior of the coatings was evaluated through three-point bending tests performed on V-notched samples coated via cold spray. Cyclic tests were performed at different maximum strokes from 0.3 to 3.6 mm in order to monitor the crack initiation and propagation during bending tests. The fracture surface aspect was analyzed by scanning electron microscopy in order to reveal the fracture mechanisms in different deformation conditions.