Nano-, micro- and macro-indentation tests of thermal spray WC-Ni coatings with lamellar microstructure at different particle deposition temperatures

The mechanical properties of WC-Ni coatings by HVOF thermal spraying were comprehensively evaluated by indentation tests at a wide load range of 10⁻¹-10³ N, i.e. nano-, micro- and macro-indentations. The correlation between process parameters and coating microstructure and mechanical properties was characterized via particle deposition temperature. The coating microstructure changes in reduced porosity, enhanced WC phase decomposition and better splats flattening were correlated to the particle deposition temperature rising. A porosity divergence between coating surface and cross-section was found as a quantitative anisotropy indicator to coating intrinsic lamellar microstructure formed by the splats flattening and piling up. Considering the lamellar microstructure, indentation responses on coating surface and cross-section were compared for hardness and elastic modulus evaluation below 3 N. The surface hardness is higher than that of cross-section, and both increased correlatively to the particle deposition temperature rising except for the almost constant surface hardness below 1 N. An analogous particle temperature-dependent behavior was also manifested for the elastic modulus by nano-indentation below 1 N. Interestingly, the elastic modulus by coating surface micro-indentation at 30 N presented identical particle temperature dependence to that by coating cross-section nano-indentation, both consistently representing the overall coating elastic modulus change trend verified by non-destructive ultrasonic test. Indentation fracture toughness on coating surface under 1.96 kN and on coating cross-section under 49 N was comparatively evaluated, and the values had a reverse trend of dependence on the particle deposition temperature. The particle-deposition-temperature dependent mechanical properties were interpreted by the coating intra-splats and inter-splats defects reduction with enhanced carbide-metal bonding essentially determined by the melting state of the metal binder phase, providing an insight to utilize indentation tests for characterizing thermal spray coatings.