Functionally graded coatings for enhanced wear resistance in AA7075 via cold spray.

• Incorporating µB 4 C particles reduced Al powder size by 14%. • SEM analysis confirmed uniform particle distribution in coatings. • Reinforcing particles decreased surface roughness by 47%. • Enhanced wear resistance was observed, reducing wear volume loss by 36%. • Coatings with nano-additives showed shallower wear tracks, lowering wear depth profile values by 28%. A compositionally graded, dual-reinforced aluminum metal matrix composite was applied onto the AA7075 substrate through cold spray. The coatings consisted of layers with varying compositions of 10, 15, and 20 vol% μB 4 C, designed to enhance wear resistance. Compositional grading of the coating extended to the top layer, which features a dual-reinforced layer comprising 2 vol% boron nitride nanotube (BNNT) and 2 vol% nB 4 C. [ABSTRACT FROM AUTHOR]