This study evaluates the potential of functionally graded composite coatings fabricated with a novel spraying process. The hybrid process embeds varying amounts of ceramic particles in a metal matrix by combining HVOF and wire arc spray streams. In this case, ceramic nanoparticles (SiO2, Cr2O3, Al2O3) from liquid precursors are embedded in a matrix synthesized from NiCr wire feedstock. The resulting coatings are evaluated based on high-temperature performance and the composition and dispersion of particles in the NiCr matrix. Uniform size distribution and dispersion of nanoparticles is shown to correlate not only with denser coatings, but also improved corrosion, wear, and oxidation resistance.

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