Comparison of hardmetal and hard chromium coatings under different tribological conditions

Electroplated hard chromium and thermal spray hardmetal coatings are widely used in a variety of applications for wear protection of component surfaces. The two protective coating types are tested in direct comparison for tribological conditions of dry abrasive wear (Taber Abraser test) and dry oscillating wear load. Oscillating wear tests are carried out both with hardened 100Cr6 steel and alumina balls as counterbody. Different types of hardmetal coatings are imparted. Besides HVOF sprayed coatings also coatings sprayed by an APS gun with axial powder feed are tested. For HVOF spraying besides standard WC/Co(Cr) feedstock also coarse (d₅₀ = 5 μm) and fine carbide feedstock (d₅₀ = 0.8 μm) and ultrafine powders, i.e. 2 μm < d < 12 μm, are considered. Use of ultrafine powders is particularly interesting from the economical point of view, as belt grinding can be sufficient for finishing in many cases. The optimum coating solution for wear protection depends on the specific tribosystem. The choice of feedstock, spraying process, equipment and processing conditions does not only depend on the resultant tribological properties. Therefore simultaneous influence on corrosion protection capability and thermal conductivity might have to be considered.