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Plasma-sprayed nickel-based self-fusion alloy coatings were annealed in a vacuum at 990, 1020 and 1050 °C for 20 min to increase the bonding between the compacted graphite cast iron substrate and coating, as well as the inner cohesion of the coatings. It was found that nickel and chromium diffused between nickel-based alloy coatings and compacted graphite cast iron substrate. A metallurgical translation zone with a thickness up to 1145 μm formed during the vacuum annealing, which resulted in an enhancement of the adhesion between the coating and substrate. The adhesion strength at room temperature was increased from the as-sprayed coating of 33.4 MPa to the annealed one of 163 MPa. Meanwhile, the adhesion strength at 500 °C reached 146 MPa. Conversely, the inner cohesion of the coating was improved with the particles’ interfaces healed after vacuum annealing. The micro-hardness of the annealed coatings was increased to 902 HV from the as-sprayed one of 578 HV.

Effect of Vacuum Annealing on the Nickel-Based Coatings Deposited on a CGI Cast Iron through Atmospheric Plasma Spraying