Research on the Microstructure and Properties of Arc-Sprayed Austenitic Stainless Steel and Nickel-Based Alloy Composite Coatings with Different Spraying Distances

1Cr18Ni9Ti and Monel composite metal coatings with five different spraying distances were prepared by arc spraying technology. The density, hardness, friction, and wear properties and acid corrosion rate of the coatings with different spraying distances were studied by X-ray diffraction, scanning electron microscopy, Rockwell hardness test, and friction and wear test. Research shows that the spraying distance has a significant effect on the density, hardness, porosity, friction, and wear properties and corrosion rate of the coating. When the spraying distance is 250 mm, the coating has the maximum density and hardness, the minimum porosity and corrosion rate, and the minimum friction coefficient and wear volume. Cu3.8ni and cr0.19fe0.7ni0.11 compounds in the coating have significant effects on the friction, wear, and hardness of the coating. The results show that too-high or too-low spraying distance will lead to pores and large particle agglomeration in the coating, which will affect the surface physical properties of the coating.