Formation Routes of Nanocomposite Coatings in Detonation Spraying of Ti3SiC2-Cu Powders

In thermally sprayed coatings, nano-sized features of the microstructure may be either inherited from the nanostructured agglomerates of the feedstock powder or form as a result of rapid cooling of molten particles upon deposition. Applying a process of the computer-controlled detonation spraying (CCDS) to Ti₃SiC₂-Cu composite powders produced by high-energy mechanical milling, we show that both routes are possible depending on the spraying conditions. When the nanostructure of the Ti₃SiC₂-Cu coating is inherited from the feedstock powder—under very mild conditions of detonation spraying, which exclude melting, so is the phase composition of the coating. In higher-temperature conditions of spraying, a significant fraction of the copper matrix melts and the interaction between Ti₃SiC₂ and Cu occurs. The TiC _x -Cu(Si) coatings that form show crystallites of both phases in the nano-range. In this case, rapid solidification of the molten fraction of the particles is responsible for the formation of the coatings with a nanostructured matrix. Due to the flexibility of the CCDS process, conditions of spraying were found such that a composite coating with very fine crystallites of the Cu(Si) matrix (30 nm) and a hardness of 273 HV could be obtained.