Research on the construction behavior and the multi-timescale tribological mechanism of Ni-based coatings on rotating components by direct current magnetic field-assisted spraying

Rotating type components are widely applied in advanced equipment manufacturing. The performance of their surface coatings directly affects the service life and operational efficiency of the equipment. To produce higher-quality surface coatings for components, this paper comprehensively combines the advantages of energy field assistance and thermal spraying, and for the first time builds a direct current magnetic field-assisted spraying equipment platform. Through the combination of experiments and simulations, it analyzes the forming mechanism and performance of supersonic plasma sprayed Ni60A coatings with and without direct current magnetic field assistance. It reveals the spreading and stacking behavior of single particles under the influence of direct current magnetic field. It also studies the tribological performance of the two coatings in multiple time dimensions. The results show that under the assistance of direct current magnetic field, the scratch wear resistance of the coating LC1 increased by 207.5 % (from 7.8328 to 24.0857), the friction coefficient in reciprocating wear decreased by 14.8 % (from 0.534 to 0.455), and the contact fatigue limit in fatigue wear increased by 10.7 % (from 1308.8 MPa to 1449.1 MPa). This research effectively improves the wear resistance and service life of the coating through the controllable construction method assisted by special energy fields. The research results provide a reliable guarantee for the stable operation of equipment under extreme environments.