Numerical and Experimental Investigations of Cold-Sprayed Basalt Fiber-Reinforced Metal Matrix Composite Coating

The aluminum-basalt fiber composite coating was prepared for the first time with basalt fiber as the spraying material by cold-spraying technology. Hybrid deposition behavior was studied by numerical simulation based on Fluent and ABAQUS. The microstructure of the composite coating was observed on the as-sprayed, cross-sectional, and fracture surfaces by SEM, focusing on the deposited morphology of the reinforcing phase basalt fibers in the coating, the distribution of basalt fibers, and the interaction between basalt fibers and metallic aluminum. The results show that there are four main morphologies of the basalt fiber-reinforced phase, i.e., transverse cracking, brittle fracture, deformation, and bending in the coating. At the same time, there are two modes of contact between aluminum and basalt fibers. Firstly, the thermally softened aluminum envelops the basalt fibers, forming a seamless connection. Secondly, the aluminum that has not undergone the softening effect creates a closed space, with the basalt fibers securely trapped within it. Moreover, the Rockwell hardness test and the friction-wear test were conducted on Al–basalt fiber composite coating, and the results showed that the composite coating has high wear resistance and high hardness.