Effect of substrate on the properties of cold sprayed coating of WC-10Ni

WC-10Ni powder was deposited on Al, Cu, and low carbon steel substrates by cold gas spray method under the process gas pressure of 15 and 35 bar. The effect of substrate on the deposition phenomenon, microstructure, and microhardness of the coatings was evaluated. The cross-section morphology of the coating was studied by the scanning electron microscopy (SEM). The pinning of WC particles caused a high strength between the coating and the substrate. Crack initiation and propagation during cold spraying process, due to the high level of cold working, was the main reason for the high level of porosity of the deposited coating on the Cu substrate. It was found that low carbon steel substrate, for its higher hardness compared to aluminium and copper, experienced minimum deformation. Moreover, the harder the substrate, the higher the microhardness and fracture toughness and the lower the porosity of the coating.