Effect of Thermally Softened Bronze Matrix on the Fracturing Behavior of Diamond Particles in Hybrid Sprayed Bronze/Diamond Composite

Abstract

In our previous study (Na et al., Compos Sci Technol 69:463-468, 2009), optimized thickness of protective nickel film was proposed for smaller diamond feedstock to obtain reduced impact stress and uniform flight behavior of particles during kinetic (or cold) spraying. However, in this study, nickel-coated diamond particles were severely fractured with increasing particle size due to high kinetic energy. Hence, an innovative hybrid spraying technique (a combination of kinetic and thermal spraying) was introduced to embed relatively large diamond particles into the bronze matrix. Size distributions of the diamond particles in the composite coatings were analyzed by scanning electron microscopy, an electron probe micro analyzer, and image analysis methods. In addition, impact behaviors of diamond particles in kinetic and hybrid gas flows were simulated through finite element analysis (ABAQUS/Explicit 6.7-2). Diamond fracturing was significantly minimized by the reduced impact energy afforded by the thermally softened bronze matrix through hybrid spraying.