Interface-tailored SiCp/Al composite coatings via cold spray: Synergistic enhanced deposition efficiency and wear resistance

β-silicon carbide particles (β-SiCp), distinguished by their unique cubic crystal structure and exceptional hardness, exhibit outstanding potential for precision tribological applications. In this study, the core-shell type SiCp-Ni composite powder was constructed by electroplating coating technology, which increased the deposition threshold of ceramic particles, effectively solved the problem of kinetic mismatch of Al/SiC two-phase deposition, mechanical locking effect and inhibition of interface fracture tendency during the cold-sprayed process, and further enhanced the cohesion of the coating. The deposition efficiency of the doped SiCp-Ni/Al composite coating is increased by 31.1 %. The core-shell structure effectively reduces the fragmentation rate of SiCp, increases the retention of SiCp by 19.1 %, improves the uniform dispersion state of SiCp, and finally obtains a densified coating with a porosity of less than 1 %. The coefficient of friction the doped SiCp-Ni/Al composite coating is reduced by 29.7 % compared with the traditional system, and the wear rate is reduced by 57.7 %. The performance improvement mechanism can be attributed to the synergistic effects of three aspects: the buffering effect of the intermediate Ni layer dissipates the impact energy, the interface bonding inhibits the shedding of abrasive particles, and the dense structure delays the failure process of the oxide layer.