This study assesses the potential of kinetic-spray coatings for dealing with the effects of soldering and erosion on aluminum casting dies. In the experiments, molybdenum-boride cermet and cobalt-based alloy powders are cold sprayed onto SKD61 substrates. Coating microstructure is assessed via SEM and XRD analysis and several mechanical properties are measured. In order to evaluate soldering resistance, the coatings are immersed in a molten aluminum bath. Although cold-sprayed CoCrNiWC exhibited high coating density and low porosity, its soldering resistance was significantly lower than that of MoB-NiCr. The boride cermet coating not only exhibited superior soldering resistance, but also higher hardness, bond strength, and wear resistance. However, its deposition efficiency needs further improvement.

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