Cavitation erosion behavior of HVAF-sprayed Cu-based glassy composite coatings in NaCl solution

Three Cu-based glassy composite coatings (C1, C2, C3) were fabricated using high velocity air-fuel (HVAF) spraying. These coatings were investigated through cavitation testing and electrochemical analysis. The analysis revealed a glassy phase, Cu0.81Ni0.19, and tetragonal-ZrO2 within these coatings. The glassy phase in C1, C2, and C3 was 50.6%, 55.4%, and 48.9%. C1 exhibited superior mechanical properties due to its high tetragonal-ZrO2 content. The microhardness of C1 measured (697 ± 50) HV0.1, with a hardness/elastic modulus ratio of 0.065 and an elastic recovery energy of (34.9 ± 1.4)%. The weight loss-time curves of C1, C2, and C3 exhibited linearity. C2 demonstrated the lowest weight-loss rate of 1.73 mg h−1, owing to its excellent corrosion resistance. Both oxidation and chloride corrosion accelerated the cavitation damage. This work highlighted the value of corrosion resistance in resisting cavitation erosion for Cu-based glassy composite coatings.