Abrasion and corrosion resistance of new Ni–based coating deposited by HVOF thermal spray process

Abstract

Coatings based on NiCrAlC intermetallic based alloy were applied on AISI 316L stainless steel substrates using a high velocity oxygen fuel torch. The influence of the spray parameters on friction and abrasive wear resistance were investigated using an instrumented rubber wheel abrasion test, able to measure the friction forces. The corrosion behaviour of the coatings were studied with electrochemical techniques and compared with the corrosion resistance of the substrate material. Specimens prepared using lower O 2 /C 3 H 8 ratios showed smaller porosity values. The abrasion wear rate of the NiCrAlC coatings was much smaller than that described in the literature for bulk as cast materials with similar composition and one order of magnitude higher than bulk cast and heat treated (aged) NiCrAlC alloy. All coatings showed higher corrosion resistance than the AISI 316L substrate in HCl (5%) aqueous solution at 40uC.

Anticorrosion of thermal sprayed Al–Zn–Si coating in simulated marine environments

“…[4][5][6][7] Zn and Al are the most commonly used materials for corrosion protection. 8,9 Separate Al coating covered by thin protective oxides functions as a barrier but is prone to pitting and mechanical damage.…”

Characterization of NiCrAlC PTA coatings

“…Powders with a grain size within the range 90-180 micrometers were mixed for 1 hour in a Y-mixer and dried at 100 °C for 48 hours to avoid agglutination. The nominal composition of the deposited powder mixture was 10% Cr, 15% Al, 8% chromium carbide and 0.1% iron boride (Ni balance), which was based on the composition of the atomized alloy used by Benegra et al 4 . PTA hardfacing on 316 L stainless steel substrate plates (100 × 80 × 7 mm…”

“…As-cast NiCrAlC alloy 3 and high velocity oxygen fuel (HVOF) thermal spray coatings 4 were tested for wear resistance and showed good wear performance at room temperature. Plasma transferred arc (PTA) hardfacing produces coatings that have a metallurgical bond with the substrate, and the processing parameters allow solidification rates to be controlled and defects typically found in thermal spray coatings and casting materials to be minimized.…”

Microstructure and wear properties of Al 2 O 3 -CeO 2 /Ni-base alloy composite coatings on aluminum alloys by plasma spray

“…As one of the most popular used coating materials in plasma spray, Ni-base alloy coatings own good wear properties both at room and high temperature [8,9], which exhibit well antiwear effects on surface strengthening of aluminum alloys, but the increasingly severe working conditions call for further enhancement in their wear resistance. Ceramic particles reinforced metal matrix composite coatings combine the high hardness and strength of ceramic particles with the good toughness of metal matrix to obtain better wear properties than the simple metal or ceramic coatings [10][11][12].…”