Nanostructured coatings

This review is based essentially on the results in the field of synthesis and characterization of nanostructured coatings obtained by the authors themselves or their colleagues. Characteristics of feedstock powders for synthesizing nanostructured coatings such as particle size and morphology, changes in chemical composition and grain size are summarized. The evolution of microstructure caused by mechanical milling in two typical powder systems, Cr3C2–NiCr and Inconel 625, and mechanisms governing the development of the nanostructure are discussed. Mechanical properties and microstructure of several nanostructured coatings are evaluated by using microhardness testing, scanning electron microscopy, transmission electron microscopy, and X-ray diffraction. As background information, a review of the agglomeration process for milled powders and of thermal spraying technologies to synthesize nanostructured coatings are also included. In addition, the methodologies used to characterize the performance of the milled powders and nanostructured coatings, as well as the practice techniques for sample preparation, are described in detail.