In this work, WC–10Co–4Cr coatings were separately deposited on 300M steel by high-velocity oxygen fuel (HVOF) and high-velocity air fuel (HVAF) spraying processes. Microstructure, porosity, micro-hardness, bonding strength, wear and corrosion resistance of the coatings after different processing were investigated and compared. The result shows that dense and homogeneous microstructure existed in both two WC–10Co–4Cr coatings. Owing to lower temperature flames and higher particle velocity in the HVAF process, the HVAF-sprayed WC–10Co–4Cr coating exhibited less decarburisation, lower porosity (0.74%), higher micro-hardness (1162 HV0.3) and bonding strength (74.68 MPa) than HVOF-sprayed WC–10Co–4Cr coating. In addition, wear and corrosion resistance of these two coatings were evaluated by sliding wear test and electrochemical corrosion test. The HVAF-sprayed WC–10Co–4Cr coating also exhibited excellent wear resistance and superior corrosion property than HVOF-sprayed WC–10Co–4Cr coating.
KumarasamyM. and NatarajanS.: ‘Selection and characterisation of HVOF cermet coatings for volutes of high capacity pumps of opencast lignite mines’, Surf. Eng., 2016,
32, 229–237.
2.
SantanaY. Y., La Barbera-SosaJ. G., BencomoA., LesageJ., ChicotD., BemporadE., Puchi-CabreraE. S. and StaiaM. H.: ‘Influence of mechanical properties of tungsten carbide–cobalt thermal spray coatings on their solid particle erosion behaviour’, Surf. Eng., 2012,
28, 237–243.
3.
RajinikanthV. and VenkateswarluK.: ‘An investigation of sliding wear behavior of WC–Co coating’, Tribol. Int., 2011,
44, 1711–1719.
4.
VerdianM. M.: ‘Characterisation and corrosion performance of HVOF sprayed Ni–10 wt-%Ti coatings’, Surf. Eng., 2014,
30, 670–674.
5.
MasukuZ. H., OlubambiP. A., PotgieterJ. H. and ObadeleB. A.: ‘Tribological and corrosion behavior of HVOF-sprayed WC-Co-based composite coatings in simulated mine water environments’, Tribol. T., 2015,
58, 337–348.
6.
HazraS., SabiruddinK. and BandyopadhyayP. P.: ‘Plasma and HVOF sprayed WC–Co coatings as hard chrome replacement solution’, Surf. Eng., 2012,
28, 37–43.
7.
BolelliG., BergerL. M., BörnerT., KoivuluotoH., LusvarghiL., LyphoutC., MarkocsanN., MatikainenV., NylénP., SassatelliP., TracheR. and VuoristoP.: ‘Tribology of HVOF- and HVAF-sprayed WC-10Co4Cr hardmetal coatings: a comparative assessment’, Surf. Coat. Technol., 2015,
265, 125–144.
8.
KumariK., AnandK., BellacciM. and GiannozziM.: ‘Effect of microstructure on abrasive wear behavior of thermally sprayed WC-10Co-4Cr coatings’, Wear, 2010,
268, 1309–1319.
9.
JafariM., EnayatiM. H., SalehiM., NahviS. M. and ParkC. G.: ‘Comparison between oxidation kinetics of HVOF sprayed WC-12Co and WC-10Co-4Cr coatings’, Int. J. Refract Met Hard Mater., 2013,
41, 78–84.
10.
StewartD. A., ShipwayP. H. and McCartneyD. G.: ‘Microstructural evolution in thermally sprayed WC-Co coatings: comparison between nanocomposite and conventional starting powders’, Acta Mater., 2000,
48, 1593–1604.
11.
Al-MutairiS., HashmiM. S. J., YilbasB. S. and StokesJ.: ‘Microstructural characterization of HVOF/plasma thermal spray of micro/nano WC–12%Co powders’, Surf. Coat. Technol., 2015,
264, 175–186.
12.
MaN., GuoL., ChengZ. X., WuH. T., YeF. X. and ZhangK. K.: ‘Improvement on mechanical properties and wear resistance of HVOF sprayed WC-12Co coatings by optimizing feedstock structure’, Appl. Surf. Sci., 2014,
320, 364–371.
13.
HongS., WuY. P., GaoW. W., WangB., GuoW. M. and LinJ. R.: ‘Microstructural characterization and micro-hardness distribution of HVOF sprayed WC-10Co-4Cr coating’, Surf. Eng., 2014,
30, 53–58.
14.
LiuS. L., ZhengX. P. and GengG. Q.: ‘Influence of nano-WC-12Co powder addition in WC-10Co-4Cr AC-HVAF sprayed coatings on wear and erosion behavior’, Wear, 2010,
269, 362–367.
15.
JacobsL., HylandM. M. and De BonteM.: ‘Study of the influence of microstructural properties on the sliding-wear behavior of HVOF and HVAF sprayed WC-cermet coatings’, J. Therm. Spray Technol., 1999,
8, 125–132.
16.
LiC. J. and YangG. J.: ‘Relationships between feedstock structure, particle parameter, coating deposition, microstructure and properties for thermally sprayed conventional and nanostructured WC-Co’, Int. J. Refract. Met. Hard Mater., 2013,
39, 2–17.
17.
SantanaY. Y., Barbera-SosaLa J. G., CaroJ., Puchi-CabreraE. S. and StaiaM. H.: ‘Mechanical properties and microstructure of WC–10Co–4Cr and WC–12Co thermal spray coatings deposited by HVOF’, Surf. Eng., 2008,
24, 374–382.
18.
PerryJ. M., NevilleA. and HodgkiessT.: ‘A comparison of the corrosion behavior of WC-Co-Cr and WC-Co HVOF thermally sprayed coatings by in situ Atomic Force Microscopy (AFM)’, J. Therm. Spray Technol., 2002,
11, 536–541.
19.
ShipwayP. H. and HowellL.: ‘Microscale abrasion–corrosion behaviour of WC-Co hardmetals and HVOF sprayed coatings’, Wear, 2005,
258, 303–312.
20.
WangQ., LiL. X., YangG. B., ZhaoX. Q. and DingZ. X.: ‘Influence of heat treatment on the microstructure and performance of high-velocity oxy-fuel sprayed WC-12Co coatings’, Surf. Coat. Technol., 2012,
206, 4000–4010.
21.
WangQ., ZhangS. Y., ChengY. L., XiangJ., ZhaoX. Q. and YangG. B.: ‘Wear and corrosion performance of WC-10Co4Cr coatings deposited by different HVOF and HVAF spraying processes’, Surf. Coat. Technol., 2013,
218, 127–136.
22.
ThakurL. and AroraN.: ‘A comparative study on slurry and dry erosion behavior of HVOF sprayed WC–CoCr coatings’, Wear, 2013,
303, 405–411.
23.
WuD. F., LiuY. S., YangS. D., YangZ. and TangH.: ‘Friction and wear characteristics of WC–10Co–4Cr/Si3N4 tribopair lubricated under silt-laden water’, Wear, 2012,
294, 370–379.
24.
YangQ., SendaT. and OhmoriA.: ‘Effect of carbide grain size on microstructure and sliding wear behavior of HVOF-sprayed WC-12% Co coatings’, Wear, 2003,
254, 23–34.
25.
AhmedR., AliO., FaisalN. H., Al-AnaziN. M., Al-MutairiS., TomaF.-L., BergerL.-M., PotthoffA. and GoosenM. F. A.: ‘Sliding wear investigation of suspension sprayed WC–Co nanocomposite coatings’, Wear, 2015,
322-323, 133–150.
26.
BolelliG., GiovanardiR., LusvarghiL. and ManfrediniT.: ‘Corrosion resistance of HVOF-sprayed coatings for hard chrome replacement’, Corros. Sci., 2006,
48, 3375–3397.
27.
HongS., WuY. P., ZhengY. G., WangB., GaoW. W. and LinJ. R.: ‘Microstructure and electrochemical properties of nanostructured WC-10Co-4Cr coating prepared by HVOF spraying’, Surf. Coat. Technol., 2013,
235, 582–588.
28.
de SouzaV. A. and NevilleA.: ‘Corrosion and erosion damage mechanisms during erosion–corrosion of WC-Co-Cr cermet coatings’, Wear, 2003,
255, 146–156.
29.
ZhangD. Q., LiuT., JooH. G., GaoL. X. and LeeK. Y.: ‘Microstructure and corrosion resistance of the brazed WC composite coatings in aerated acidic chloride media’, Int. J. Refract. Met. Hard Mater., 2012,
35, 246–250.
30.
LiuS. L. and ZhengX. P.: ‘Microstructure and properties of AC-HVAF sprayed Ni60/WC composite coating’, J. Alloys Compd., 2009,
480, 254–258.
31.
ChoJ. E., HwangS. Y. and KimK. Y.: ‘Corrosion behavior of thermal sprayed WC cermet coatings having various metallic binders in strong acidic environment’, Surf. Coat. Technol., 2006,
200, 2653–2662.
