Microstructures of Metallic NiCrBSi Coatings Manufactured via Hybrid Plasma Spray and In Situ Laser Remelting Process

This paper deals with coating alternatives to hard chromium plating. Thermal spraying is already used in industry, but results are not always satisfactory for reasons of porosity and microstructures. In this study, atmospheric plasma spraying (APS) and in situ laser irradiation by diode laser processes were combined to modify the structural characteristics of thick NiCrBSi alloy layers. The microstructure evolution was studied, and results show that in situ laser remelting induced the growth of a dendritic structure, which strongly decreased the porosity of as-sprayed coatings and increased the adhesion on the substrate. Moreover, no phase transition after laser treatment was observed. Lastly, a mechanical investigation demonstrated that the combination between plasma spray and in situ melting with a diode laser could result in very good mechanical properties. The increase of the laser incident power involved an increase of the mean contact pressure, along with coating hardness. The hybrid process appears to be a possible alternative to hard chromium plating, in order to protect mechanical parts, because of the improved mechanical properties of the NiCrBSi layer.