Research on the performance of plasma-sprayed Aluminum Bronze Polyester coating

The CuAl/PHB coating was fabricated via atmospheric plasma spraying technique. The coating's microstructure, hardness, bond strength, high-temperature oxidation resistance, water quenching thermal shock resistance, high-temperature hardness, fretting wear, and abradability were meticulously examined and analyzed. Observations indicated that the CuAl/PHB coating contained 17.5% porosity and polyester constituent. The average hardness of the coating measured at 90.4 HR15Y, while the bond strength surpassed 26.4 MPa. Notably, the coating demonstrated commendable resistance to high-temperature oxidation at 620 °C and endured 135 cycles of water quenching thermal shock at 700 °C. Moreover, the coating exhibited a declining trend in high-temperature hardness from HR15Y 76.6 to 66.8 within the temperature range of 450 °C to 700 °C. Furthermore, the fretting wear test conducted under a substantial load of 100 N and high frequency of 100 Hz, spanning from room temperature to 700 ℃, revealed a friction coefficient below 0.5 at 620 °C, unequivocally indicating superior and consistent resistance against fretting wear. Additionally, the coating displayed favorable abradability characteristics under simulated operating conditions between 400 °C and 650 °C, exhibiting a blade feed wear ratio (IDR) lower than 21.2%. Remarkably, as the temperature increased, the abradability of the coating witnessed an increment.