Microstructure and Wetting Performance of High-Pressure Cold Sprayed Quasi-Crystalline Composite Coatings

High-pressure cold spraying has shown significant potential in manufacturing metallic composite coatings for a wide range of industrial applications, including wear and corrosion protection. Quasi-crystalline materials, in turn, are promising candidates due to their unique microstructural features. Combining these concepts, metallic compo- site coatings were generated using high-pressure cold spraying to produce functional and protective coatings. Several spray trials were done to detect the effect of compositions and size of quasi-crystalline feedstock materials mixed with metal powders, Al6061, and stainless steel 316L, on coating microstructure, integrity, and surface properties. A scanning electron microscope was used to examine the microstructure of the feedstock materials and composite coatings. A 3D surface optical profilometer was also used to investigate surface texture. The wettability of the coating surfaces was measured by static water contact angles using a droplet shape analyzer. Cold-sprayed quasi-crystalline composite coatings showed denser and well-integrated deposits with a random distribution of phases across the composite surface, indicating promising structural reliability and hydrophobic behavior.