Tribological Characterization of WC–Co Plasma Sprayed Coatings

Atmospheric plasma spraying of WC coatings is typically characterized by increased decarburization, with a consequent reduction of their wear resistance. Indeed, high temperature and oxidizing atmosphere promote the appearance of brittle crystalline and amorphous phases. However, by using a high helium flow rate in a process gas mixture, plasma spraying may easily be optimized by increasing the velocity of sprayed particles and by reducing the degree of WC dissolution. To this purpose, a comparative study was performed at different spray conditions. Both WC–Co powder and coating phases were characterized by X-ray difraction. Their microstructure was investigated by scanning electron microscopy. Mechanical, dry sliding friction, and wear tests were also performed. The wear resistance was highly related to both microstructural and mechanical properties. The experimental data confirmed that high-quality cermet coatings could be manufactured by using optimized Ar–He mixtures. Their enhanced hardness, toughness, and wear resistance resulted in coatings comparable to those sprayed by high velocity oxygen-fuel.     

Surface and cross–section characteristics and friction–wear properties of high velocity oxy fuel sprayed WC–12Co coating

A WC–12Co coating was sprayed on H13 hot work mould steel using a high velocity oxy fuel (HVOF). The surface and cross–section morphologies, chemical compositions, and phases of obtained coatings were analyzed using a field emission scanning electron microscope (FESEM), energy dispersive spectrometer (EDS), and X–ray diffraction (XRD), respectively. The friction–wear properties were investigated using a wear test, the wear mechanism of WC–12Co coating was also discussed. The results show that the WC–12Co coating primarily is composed of WC hard phase with high hardness and Co as a binder, which is evenly distributed on the coating surface, no atom–rich zones. There is no W₃O phase appearing in the HVOF spraying, showing that the WC–12Co coating has high oxidation resistance, the new phases of W₂C and C are produced due to the decarburization of WC. The coating thickness is ~200 μm, which is combined the substrate with the mechanical binding and local micro–metallurgical bonding. The average coefficient of friction (COF) of WC–12Co coating is 0.272, showing good friction performance, the wear mechanism is primarily abrasive wear, accompanied with fatigue wear.     

Wet abrasive wear behavior of WC-based cermet coatings prepared by HVOF spraying

In this study, three kinds of WC-based cermet coatings including WC–CoCr coating, WC–Ni coating and WC–Cr₃C₂–Ni coating were prepared by the high-velocity oxygen-fuel (HVOF) spraying process. Scanning electron microscopy (SEM), energy disperse spectroscopy (EDS) and Vickers hardness tester were used to analyze the microstructure and mechanical properties of these coatings. The WC–CoCr coating presented the highest average microhardness of 1205 HV_0.3, and then followed by the WC–Cr₃C₂–Ni coating (1188 HV_0.3) and the WC–Ni coating (1105 HV_0.3). The abrasive wear behavior of the WC-based coatings under the conditions of different applied loads and sediment concentrations were studied by a wet sand-rubber wheel tester. The results indicated that the abrasive wear loss rates of all the coatings increased with the increment of applied load or sediment concentration. In addition, the coatings with higher microhardness appeared to have higher abrasive wear resistance. The abrasive wear resistance of the WC-based coatings was 4–90 times higher than that of AISI 304 stainless steel under the same testing condition. The abrasive wear mechanism of the WC-based coatings was deduced to be the extrusion and removal of binder phases, as well as the fragmentation and peel-off of hard phases.     

A study of CVD diamond deposition on cemented carbide ball-end milling tools with high cobalt content using amorphous ceramic interlayers

In this paper, CVD diamond coatings are deposited on cemented carbides with 10 wt.% Co using amorphous SiO₂ and amorphous SiC interlayers. Transmission electron microscopy (TEM), scanning electron microscopy (SEM), energy dispersive X-ray (EDX), Raman spectrum and X-ray diffraction (XRD) are carried out to characterize the microstructure and composition of as-deposited films. Moreover, the adhesion and cutting performance of as-fabricated diamond coatings are studied. Indentation tests show that the amorphous ceramic interlayers can enhance the adhesion between diamond films and WC–Co substrates. The cutting tests against zirconia indicate that the tools with amorphous ceramic interlayered diamond coatings exhibit improved cutting performance. The amorphous ceramic interlayers can improve the adhesive strength and wear endurance of diamond coatings on WC–10 wt.% Co substrates, which provide a viable way for adherent diamond coatings on cemented carbide tools with high cobalt content.     

Influence of Y2O3 on the microstructure and tribological properties of Ti-based wear-resistant laser-clad layers on TC4 alloy

Multi-track Ti-based wear-resistant composite coatings were fabricated on TC4 alloy surfaces using laser-clad TC4 + Ni45 + Co–WC mixed powders with different Y₂O₃ contents (0, 1, and 3 wt%). The microstructure, microhardness, and tribological properties of the coatings were characterised using X-ray diffraction, scanning electron microscopy, energy dispersive spectrometry, electron probe X-ray micro analyser, microhardness tester, and friction and wear testing apparatus. The results showed that the number of cracks on the coating surfaces gradually decreased with the addition of Y₂O₃ and that residual Co–WC powders existed in the coating subsurfaces. The phase composition of the coatings with different Y₂O₃ contents remained unchanged and was mainly composed of reinforcing phases of TiC, TiB₂, Ti₂Ni, and matrix α-Ti. With the addition of Y₂O₃, the coating microstructure was remarkably refined, the direction characteristic of the TiC dendrites obviously weakened, and the nucleation rate significantly increased. When the added Y₂O₃ was 3 wt%, a large amount of TiB₂–TiC-dependent growth composite phases precipitated in the coating. The two-dimensional lattice misfit between (0001)_TiB2 and (111)_TiC was 0.912%, which indicated that TiB₂ and TiC formed a coherent interface. When the amount of Y₂O₃ was increased, the microhardness of the coatings gradually decreased, and the wear volume of the coatings first increased and then decreased. Under the effect of the TiB₂–TiC composite phases, the wear resistance of the 3 wt% Y₂O₃ coating was optimal. The 3 wt% Y₂O₃ coating friction coefficient was the lowest, and the wear mechanism was abrasive wear.     

Microstructure and wear properties of plasma‐sprayed aluminum–silicon–polyester coatings

Powder coatings, which are made by plasma‐spraying processes, are being used in industrial applications because of their wear resistance, chemical resistance, and high impact strength even at low service temperatures. These factors increase the importance of plastic and plastic‐based coatings in industrial applications. In this study, an aluminum–silicon–polyester‐based composite coating was applied by plasma‐spraying processes with and without an intermediate bond coat (Ni–Al). The effects of the coating thickness, intermediate bond coat, and processes parameters on the microstructure and wear properties of the coating were studied experimentally. The wear properties of the coatings were determined according to ball‐on‐disk procedure. The microstructures of the coating were examined by optical microscopy and scanning electron microscopy. The results indicated that the plasma‐spraying current and thickness had a strong influence on the wear resistance and microstructural properties of the aluminum–silicon–polyester coating. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 3609–3614, 2006     

Microstructural Properties of Air Plasma Sprayed Coating Consisting of Tungsten Carbide and Yttria‐Stabilized Zirconia

Thermal Spraying technologies are proven to be capable of producing composite materials and structures. In the present work, an innovative composite coating was produced to achieve high wear and thermal resistant properties in a single‐step process using air plasma spraying (APS) technique. Tungsten carbide has shown high wear resistance and zirconia coatings exhibited excellent tribological and insulation properties. It is speculated that a composite material consisting of zirconia and tungsten carbide exhibits excellent thermomechanical properties. A powder mixture of 50wt% WC‐10wt% Ni (WC‐Ni) and 50wt% ZrO₂‐8wt% Y₂O₃ (YPSZ) was deposited on a low carbon steel substrate using APS technique. Important microstructural properties of WC‐Ni/YPSZ coating such as splat boundaries, pore and grain morphology, microcracks, phase composition, elemental distribution of coatings, and lattice parameters of the crystals were investigated using optical microscopy, scanning electron microscopy (SEM), energy dispersive X‐ray (EDS), and X‐ray diffractometry (XRD). A good adhesion was observed between different phases in tungsten carbide mixed with zirconia coatings. Decarburization process which occurred during APS process resulted in formation of tungsten hemi‐carbide (W₂C) phase in plasma sprayed samples. The calculated crystal size for APS‐deposited coating was smaller than those of feedstock powder.     

Mechanical Properties of Plasma‐Sprayed Mullite‐Reinforced Titania–Bioglass Composite

Bioceramics have been extensively used for various medical applications including hip and knee prostheses, tissue engineering scaffolds, and dental implants. Bioceramics, particularly bioglass, are desired because of their bioactivity but are often limited by their inherent brittleness. To compensate, composites have been formed to obtain unique properties where both bioactivity and mechanical integrity can be achieved. Mullite‐reinforced titania–bioglass (TiO₂–BG) composites were therefore deposited using plasma spraying technique. The microstructure of the coating materials were analyzed for their morphology and microstructure using scanning electron microscopy/energy dispersive spectrometry. Mechanical properties of the coatings were tested using three‐point bend test, indentation test, and pin‐on‐disk wear test to determine their fracture strength, fracture toughness, and wear resistance, respectively. The addition of mullite fibers improved the fracture strength and wear resistance of TiO₂–BG composites while having minimal effect on fracture toughness. After the addition of mullite, failure mode was bimodal, failing intergranularly and by fiber pull‐out. Although mullite fibers have not been particularly used for medical applications, fiber reinforcement has shown efficacy in mechanically reinforcing composites of various medical applications.     

Effect of the Cubic Phase Distribution on Ultrafine WC–10Co–0.5Cr–xTa Cemented Carbide

The (Ta, W)C cubic phase distribution plays a key role in the microstructure and mechanical properties of ultrafine WC–Co–Cr₃C₂–TaC cemented carbides. By integration of thermodynamic calculations and key experiments, the influence of the cubic phase distribution in ultrafine WC–10Co–0.5Cr–xTa cemented carbides was systematically investigated. A series of ultrafine grained cemented carbides were designed and fabricated through ball‐milling and vacuum sintering at 1410°C for 1 h. The microstructure was investigated using scanning electron microscopy (SEM). The electron backscattered diffraction (EBSD) was used to measure the orientation and size of cubic phase segregation. The results indicate that the cubic phase in the microstructure distributes more heterogeneously in the range of 0.2 to 0.7 wt% Ta addition, but finally the isolated cubic phase is homogeneously distributed with a Ta content from 0.7 to 1 wt%. Combining the thermodynamic calculation with the experiment, the mechanism for the microstructure evolution has been revealed. The mechanical properties of alloys substantially depend on the cubic phase distribution in the microstructure. A synergetic correlation between the transverse rupture strength (TRS) and Rockwell hardness was observed. The homogeneity of cubic phase can be designed and controlled effectively via the present approach.     

Effect of laser power on microstructure and tribological performance of WC−10Co4Cr coating

In order to enhance wear resistance of cold work molds, WC−10Co4Cr coating was fabricated on Cr12MoV steel by laser cladding. The morphologies, chemical compositions, and phases of obtained coatings were analyzed using a scanning electron microscopy (SEM), energy disperse spectroscopy, and X−ray diffraction, respectively. The effect of laser power on the tribological performance was analyzed using a ball−on−plate friction machine, and the wear mechanism was also discussed. The results show that the WC−10Co4Cr coating is composed of WC and Co₆W₆C phases, and the average hardness of coating cross−sections fabricated at the laser power of 1200, 1500, and 1800 W was 1296, 1375, and 1262 HV_0.5, respectively, in which that fabricated at the laser power of 1500 W is the highest among the three kinds of coatings. The average coefficients of friction of coatings fabricated at the laser power of 1200, 1500, and 1800 W are 0.61, 0.52, and 0.59, respectively; and the corresponding wear rates are 64.38, 35.38, and 123.92 μm³•N⁻¹•mm⁻¹, respectively, showing that the coating fabricated at the laser power of 1500 W has best friction reduction and wear resistance. The wear mechanism of WC−10Co4Cr coating is fatigue wear and abrasive wear, which is contributed to the increase of hard WC mass fraction.     

A comparative investigation on microstructure evolution and wear resistance of in situ synthesized NbC,WC, TaC reinforced Mo2FeB2 coatings by laser cladding

To improve the microhardness and wear resistance of Mo₂FeB₂ coatings, composite coatings were prepared by laser cladding using in situ synthesized NbC, WC, and TaC. The influence of different carbides on the morphology, microstructure, microhardness, residual stress, and tribological properties of the composite coatings was investigated. The results showed various microstructural morphologies in different composite coatings. Apparent herringbone structures were observed in most coatings except for the Mo₂FeB₂/TaC composite coating and a eutectic structure was formed in the Mo₂FeB₂/WC composite coating. In addition, the heat-affected zone was typically composed of acicular martensite and lath martensite. The microhardness of the Mo₂FeB₂/WC composite coating increased to 1543.6 HV_0.5 compared with 985.7 HV_0.5 observed for the Mo₂FeB₂ coating. Tensile stress existed in the coating, bonding zone, and heat-affected zone, whereas the substrate exhibited compressive stress. The Mo₂FeB₂/WC composite coating exhibited the lowest tensile stress (298 MPa). The Mo₂FeB₂/WC composite coating containing WC and the W₂C phase had the lowest coefficient of friction (0.38) and wear rate (3.90 × 10^?5 mm³/Nm), indicating its excellent tribological properties. Moreover, the wear mechanism of the Mo₂FeB₂ coating is severe adhesive and abrasive wear. The adhesive wear mechanism was mitigated by the formation of in situ synthesized NbC, WC, and TaC. The wear mechanism of the Mo₂FeB₂/WC composite coating was only a slight abrasive wear.     

Microstructure and properties of Ni-WC gradient composite coating prepared by laser cladding

In this study, an Ni-based gradient composite coating reinforced with WC was prepared on a Q345R steel substrate by laser cladding. The Ni-WC composite coating was designed as a multilayer structure with gradient composition. The coating started with a layer of C276 alloy with 10 wt% WC on the substrate, and the subsequent layers were composed of Ni60 alloy with different WC contents (10, 30, and 50 wt% WC). The overall morphology, phase composition, and microstructure of the coatings were investigated. The microhardness and the wear properties of each layer of the coatings were also evaluated. The results showed that the gradient composition design was beneficial for reducing the cracking tendency. The coating was composed of an Ni-based matrix, WC, and multiple carbides and borides hard phases. With increasing WC content in the layers, the hard phases exhibited regional distribution characteristics. The WC reinforcement particles underwent different types of dissolution during the cladding process. From the surface to the substrate, the average microhardness of the coating was 1053.5 HV_0.2, 963.4 HV_0.2, 859.0 HV_0.2, 441.7 HV_0.2, and 260.5 HV_0.2. The wear tests revealed that the coefficient of friction and the wear loss values of the four layers were all lower than those of the substrate, demonstrating enhanced wear resistance.     

Friction behavior of PTFE-coated Si3N4/TiC ceramics fabricated by spray technique under dry friction

PTFE coatings were deposited on the Si₃N₄/TiC ceramic substrate by using spray technology. The surface and cross-section micrographs, adhesive force of coatings with substrate, surface roughness and micro-hardness of the coated ceramics were examined. The friction and wear behaviors of ceramic samples with and without coatings were investigated through carrying out dry sliding friction tests against WC/Co ball. The test results indicated that the coated ceramics exhibited rougher surface and lower micro-hardness, and the PTFE coatings can significantly reduce the surface friction and adhesive wear of ceramics. The friction performance of PTFE-coated sample was affected by applied load due to the lower surface hardness and shear strength of coatings, and the main wear failure mechanisms were abrasion wear, coating delamination and flaking. It can be considered that deposition of PTFE coatings is a promising approach to improve the friction and wear behavior of ceramic substrate.     

Strongly adherent Al2O3 coating on SS 316L: Optimization of plasma spray parameters and investigation of unique wear resistance behaviour under air and nitrogen environment

Plasma spray deposition of Al₂O₃ is a well-established technique for thick ceramic coatings on various substrates to shield them from corrosion and wear. Owing to its high hardness, aluminum oxide is known to protect stainless steel substrates from wear. However, the plasma process requires optimization for desired coating thickness and adhesion strength. It is also necessary to understand the sensitivity of friction and wear resistance of the deposited coating on exposed environment for evaluation of service life. The study offers comprehensive investigation on plasma process parameters for the development of strongly adherent aluminium oxide coatings on SS 316L substrate. Impact of environment like dry air and dry nitrogen on tribological properties of the coatings was also investigated. Dense adherent coatings of alumina could be deposited on SS 316L at a plasma power of 20 kW with an intermediate bond coat of NiCrAlY to enhance the adhesion properties. The effects of stand-off distance and bond coat thickness on adhesion strength were additionally examined. Further, the coatings were characterised for phase composition, microstructure, microhardness and wear resistance potential. Reciprocating wear tests of the coatings were carried out using ball on disc reciprocating tribometer at different loading conditions (5, 10 and 15 N) at constant (5 Hz) sliding frequency. Unlike the coefficient of friction (COF), wear volume was found to increase with an increase in normal load. These adherent coatings revealed promising properties for the applications where the tribological failure of SS 316L in dry air or dry nitrogen environment is to be controlled.     

Engineering nanostructured thermal spray coatings: process–property–performance relationships of ceramic based materials

Abstract

Nanostructured powders were deposited using thermal spraying to produce coatings having internal features of nanosized dimensions. Several ceramic based materials were studied, including WC–12 wt-%Co, TiO₂, hydroxyapatite, Al₂O₃–13 wt-%TiO₂ and yttria stabilised zirconia. The effect of the thermal spray conditions on the microstructure, phase composition, properties and performance was investigated. Key nanostructural features of the coatings were identified and their potential benefit in contributing to enhanced behaviour explored. Issues relating to design strategies and process control for engineering these types of coatings with performance characteristics tailored for targeted applications are discussed.     

Growth and Microstructure‐Dependent Hardness of Directionally Solidified WC–W2C Eutectoid Ceramics

Directionally solidified WC–W₂C ceramics containing 40 at% carbon, corresponding to the WC–W₂C eutectoid composition, were produced by laser surface melt processing. The resulting microstructures showed a lamellar‐type eutectic/eutectoid microstructure with the WC minor phase embedded in the W₂C matrix phase. The interlamellar spacing (λ) in the eutectoid regions followed the relationship Vλ^3.8 = constant, with the smallest spacing of 331 ± 36 nm achieved in the 3.24 mm/s processed sample. The indentation hardness increased with decreasing interlamellar spacing, and a Vickers indentation hardness of 28.5 GPa was achieved in the sample with the smallest interlamellar spacing. The directionally solidified WC–W₂C materials show enhanced indentation mechanical properties in comparison to previously reported WC–Co composites and WC‐based materials.     

Effects of WC addition on the erosion behavior of high-velocity oxygen fuel sprayed AlCoCrFeNi high-entropy alloy coatings

In this study, AlCoCrFeNi (H1), AlCoCrFeNi+25 wt%WC-10Co (H2), and AlCoCrFeNi+50 wt%WC-10Co (H3) high-entropy alloy (HEA)/tungsten carbide (WC) composite coatings were deposited onto 316 stainless steel substrates by applying the high-velocity oxygen fuel spraying technology. The phase, layered microstructure, microhardness, and erosion behavior of the coatings were analyzed by performing X-ray diffractometry, scanning electron microscope/energy dispersive spectrometry, Vickers microhardness testing, and slurry erosion testing. The effects of WC addition on the erosion behavior and mechanism of the coatings at different flow velocities were investigated. The deposited coatings were compacted and adhered well to the substrate. The AlCoCrFeNi coating was composed of BCC and FCC phases. The porosity of the H1, H2 and H3 coatings were 0.24%, 0.33% and 0.45%, respectively, and were less than 1%. The microhardness of the HEA/WC composite coatings was positively correlated with WC content. The volume loss and rate of volume loss of the coatings decreased with the addition of WC. The erosion mechanism of the AlCoCrFeNi coating was typical ductile wear, with a small amount of interlayer peeling. Furrows, cuttings, and plastic deformation caused by low grazing angles contributed to the failure of the AlCoCrFeNi coating. In the HEA/WC composite coatings, WC protected the HEA from more severe plastic deformation by second-phase strengthening, and the main erosion mechanism of WC was gradual brittle detachment caused by high-grazing-angle erosion in which craters, cracks, and massive spalling were responsible for the erosion process.     

Titanium carbide/duplex stainless steel (DSS) metal matrix composite coatings prepared by the plasma transferred arc (PTA) technique: microstructure and wear properties

The present investigation focuses on the microstructure and the tribological properties of TiC/steel composite coatings obtained on 2205 duplex stainless steel (DSS) substrate, by using the plasma transferred arc technique. Two different plasma and shielding gas mixtures have been used, namely (a) 100% Ar and (b) 95% Ar + 5%N₂. The coatings obtained are defect-free and their thickness is 1.50 ± 0.05 mm. Both coatings consist of a dispersion of TiC _x N _y particles, with a volume fraction of about 18–22%, in an austenite–ferrite matrix. The austenite-to-ferrite volume fraction is 35/65% for the Ar coatings and it is found to increase to 40/60%, when nitrogen is used in the plasma and shielding gas. The hardness of the composite coatings is improved significantly (630–650HV on average) compared to the hardness of the substrate (250HV). The friction coefficient produced against an Al₂O₃ counterbody has decreased considerably to 0.2–0.3 from 0.5 for the 2205/Al₂O₃ pair and the wear rate was reduced at least by one order of magnitude with respect to the value of the 2205 DSS substrate.     

Effect of MoS2/PTFE coatings on performance of Si3N4/TiC ceramics in dry sliding against WC/Co

To enhance the tribological performance of Si₃N₄/TiC ceramics, MoS₂/PTFE composite coatings were deposited on the ceramic substrate through spraying method. The micrographs and basic properties of the MoS₂/PTFE coated samples were investigated. Dry sliding friction experiments against WC/Co ball were performed with the coated ceramics and traditional ones. These results showed that the composite coatings could significantly reduce the friction coefficient of ceramics, and protect the substrate from adhesion wear. The primary tribological mechanisms of the coated ceramics were abrasive wear, coating spalling and delamination, and the tribological property was transited from slight wear to serious wear with the increase of load because of the lower surface hardness and shear strength. The possible mechanisms for the effects of MoS₂/PTFE composite coatings on the friction performance of ceramics were discussed.     

Nanostructure,mechanical and tribological properties of reactive magnetron sputtered TiCx coatings

This study describes the correlation between microstructure, mechanical and tribological properties of TiC_x coatings (with x being in the range of 0–1.4), deposited by reactive magnetron sputtering from a Ti target in Ar/C₂H₂ mixtures at ~ 200 °C. The mechanical and tribological properties were found to strongly depend on the chemical composition and the microstructure present. Very dense structures and high hardness, combined with low wear rates and friction coefficients, were observed for coatings with chemical composition close to TiC. X-ray diffraction and X-ray photoelectron spectroscopy analysis, used to evaluate coating microstructure, composition and relative phase fraction, showed that low carbon contents in the coatings lead to sub-stoichiometric nanocrystalline TiC_x coatings being deposited, whilst higher carbon contents gave rise to dual phase nanocomposite coatings consisting of stoichiometric TiC nanocrystallites and free amorphous carbon. Optimum performance was observed for nanocomposite TiC_1.1 coatings, comprised of nanocrystalline nc-TiC (with an average grain size of ~ 15 nm) separated by 2–3 monolayers of an amorphous a-DLC matrix phase.