Tribological behavior of plasma spray coatings for marine diesel engine piston ring and cylinder liner

High-temperature wear characteristics between plasma spray coated piston rings and cylinder liners were investigated to find the optimum combination of coating materials using the disc-on-plate reciprocating wear test in dry conditions. The disc and plate represented the piston ring and the cylinder liner, respectively. Coating materials studied were Cr₂O₃-NiCr, Cr₂O₃-NiCr-Mo, and Cr₃C₂-NiCr-Mo. Plasma spray conditions for the coating materials were established adjusting stand-off distance to obtain a coating with a porosity content of ∼5%. It was found that a dissimilar coating combination of Cr₂O₃-NiCr-Mo and Cr₃C₂-NiCr-Mo provided the best antiwear performance. The addition of molybdenum was found to be beneficial to improve the wear resistance of the coating. Hardness differences between mating surfaces were also important factors in determining the wear characteristics, so that it should be controlled below 300 in Vickers hardness under dry conditions. Adhesive wear accompanying with metal transfer was a dominant wear mechanism for dry conditions.