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NiAl-based intermetallic coatings were obtained using non-vacuum electron beam cladding on low-carbon steel. The structure of the coatings was investigated using optical microscopy, scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), electron backscatter diffraction (EBSD), and X-ray diffraction (XRD). The coatings mostly consisted of grains elongated perpendicular to the substrates, with a strong <100> texture along the grain growth direction. The coatings contained about 14 at. % Fe, which appeared due to the partial melting of the steel substrate. At the bottom of the coatings, an inhomogeneous mixing zone with an increased concentration of Fe was formed; at the "substrate–coating" interface, a thick layer with a Fe50-Ni25-Al25 at. % composition was observed. The samples exhibited weight gains of 0.1, 0.8, 2.14, and 3.4 mg/cm2 after 100 h of oxidation at 700, 800, 900, and 1000 °C, respectively. The oxide layer contained α-Al2O3 and θ-Al2O3, and the presence of iron atoms contributed to the formation of a small amount of spinel. During the oxidation process, a layer with a high Fe content (~60 at. %) formed along the boundary between the oxide film and the NiAl-based material, which had a positive effect on the formation of a non-porous "oxide–coating" interface. [ABSTRACT FROM AUTHOR]

A comparison of the numerical simulation and an experimental study of the collision of the particles and the substrate during detonation spraying is presented. The spraying regimes were chosen to provide unmelted, partially melted, and completely molten particles. The numerical simulation was performed using the smoothed particle hydrodynamics (SPH) method with velocity and temperature settings as initial conditions. Good agreement was obtained between the simulation results and the experimental data, making the SPH simulation suitable for analysis of the deformation of particles and the substrate during detonation spraying. Information about the particle's shape evolution during the collision is presented. An increase in temperature and plastic strain is analyzed at different points of the particle and substrate. Under certain spraying regimes, it is possible to melt a solid particle due to its high-strain-rate deformation, but no melting of the substrate was observed during the simulation. [ABSTRACT FROM AUTHOR]