Tribological behavior of HVOF- and HVAF-sprayed composite coatings based on Fe-Alloy + WC-12% Co

Fe-based coatings are promising alternatives to Ni-based ones, because of lower cost and lower toxicity. Following a previous research, where the sliding wear resistance of HVOF-sprayed Fe-Cr-Ni-Si-B-C alloy coatings was found to compare favorably with that of a Ni-Cr-B-Si-C alloy and of electroplated chromium, the present study investigates the wear resistance of Fe-Cr-Ni-Si-B-C + WC-Co composite coatings. The Fe-alloy feedstock powder was therefore blended with 0, 20 and 40 wt.% of a WC-12 wt.% Co powder and sprayed by HVOF and HVAF processes. HVAF-sprayed coatings exhibit less structural alteration than HVOF-sprayed ones, which results in lower intrinsic nanohardness of both Fe-alloy and WC-Co splats; however, HVOF- and HVAF-sprayed coatings exhibit similar Vickers microhardness. Somewhat poorer interlamellar bonding in HVAF-sprayed coatings results in a greater tendency to microcracking during dry sliding wear testing at room temperature; however, dry sliding wear rates of HVOF- and HVAF-sprayed samples never differ significantly. The reinforcing effect of WC-Co decreases the wear rate of composite coatings (approximate to 10(-6) mm(3)/(Nm)) by more than order of magnitude, compared to unreinforced ones (approximate to 1-2 * 10(-5) mm(3)/(Nm)). As the test temperature is increased to 400 degrees C and 700 degrees C, the dry sliding wear rates of all samples increase (up to 10(-4) mm(3)/(Nm) or greater). The greatest changes are observed when the WC-Co content is larger, as it suffers from oxidation and thermal alteration more than the Fe-alloy matrix. The abrasive wear resistance of the Fe-based coatings, evaluated by rubber-wheel testing, is also significantly improved by the addition of WC-Co. (C) 2014 Elsevier B.V. All rights reserved.