The aim of this study is to evaluate the effect of electromechanical treatment on the structure and wear behavior of plasma-sprayed nickel coatings. The coatings were air plasma sprayed on low carbon steel substrates, then electromechanically treated using different values of current density. Erosion resistance was assessed based on volume loss and coating microstructure and phase composition were evaluated via SEM and XRD. Erosion mechanisms were compared by analyzing coating cross-section and surface microstructures and wear resistance was associated with features such as defects, porosity, and cracks.

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