Multi-layer formation by oxidation and solid-state crystallization of cold sprayed amorphous coatings during dry sliding wear

Amorphous alloy coatings, known for the exceptional wear resistance, have emerged as a key solution for enhancing the wear performance of magnesium alloys under harsh environments. In this study, Fe-based amorphous alloy coatings were deposited on magnesium alloy by cold spraying technology, and the influence of microstructural evolution on the wear performance of coatings under dry sliding wear conditions was discussed. The results showed that a dense adherent oxide layer with a thickness of ∼700 nm comprising nanograins of less than 8 nm was formed at the outmost surface, which played a role of self-lubricating. Underneath, a 1 μm thick nanocrystalline-amorphous layer with nanograins of ∼20 nm dispersed in the amorphous alloy matrix was formed through in-situ crystallization induced by flash temperature. This composite structure prevented the formation of shear bands in amorphous alloys and enhanced the durability. Therefore, the transition from abrasive wear to adhesive wear was a consequence of the microstructural evolution from a dual-phase composite layer to a self-lubricating oxide layer.