Highly efficient solid-state fabrication of aluminum alloy reinforced by tungsten carbide particulate via cold spray deposition: Microstructure and wear resistance

In this work, we fabricated aluminum alloy (AA6061) reinforced by tungsten carbide (WC)-based particulate through a single-step cold spraying of a 1:1 volumetric powder blend. The key findings were exceptionally thickness build-up, densification, hardness gain and reinforcement retention, nearly matching the ratio in the initial blend as compared to more conventional benchmark, cold sprayed AA6061-Al 2 O 3 . That intense plastic deformation from the impact of spherical WC particles triggered efficient dynamic recrystallization within the Al alloy matrix with dominancy of high angle grain boundaries within the matrix and close to the reinforcement interface, potentially contributing to strengthening the matrix. Both coatings have experienced similar wear modes of adhesive, abrasive and oxidative wear. However, the specific wear rate of WC particulate reinforced matrix was reduced by 50% compared to the Al 2 O 3 reinforced matrix, due to superior hardness, enhanced coating integrity, stability of tribofilm and microstructural refinement. This remarkable deposition efficiency and reinforcement retention, achieved without complex particle pre-treatments, establishes a promising pathway for the additive manufacturing of high-performance and wear-resistant aluminum-based components. • WC-based particulates were used to reinforce Al alloy (AA) matrix by cold spray (CS) • WC particulates were tightly bonded to Al alloy matrix via a single step CS deposition • Retention of reinforcement and deposition efficiency was surprisingly high for AA-WC • Superior densification, hardness and grain refinement in WC-reinforced composite. • AA-WC displayed a reduced specific wear rate (half of AA-Al 2 O 3 )