Effect of adding boron carbide on some physical and mechanical properties of a metal-based system using the flame thermal spray method

This study investigated the effect of boron carbide addition on some physical and mechanical properties of a metal-based system using the flame thermal spray method. The flame spray thermal technology was used to treat the cracks and corrosion that occurred in the turbine blades. Doing by preparing a nickel Ni coating reinforced with boron carbide B4C, where the binding material is 80% Ni-20% Al with a thickness of 0.1-0.3 mm. The primer and support material was sprayed onto the bases of the turbine blades, and a final thickness of the samples of 1.45 mm was obtained. Hardness, porosity, and adhesion strength are tested before heat treatment. The highest hardness value 202 Hv, the lowest porosity value 11%, and the highest adhesion strength value 28 MPa were obtained at 25%. Heat treatment was performed at 1000 °C for two hours, then the test was repeated, as we noticed an increase in the hardness value and adhesion strength to 260 Hv and 52 MPa, respectively, and the porosity decreased to 5%. Also, X-ray diffraction XRD and scanning electron microscopy SEM were examined. The XRD results showed the appearance of nickel and boron carbide, as well as the emergence of new phases at each ratio.