The demand for stainless steel in technical applications has increased to improve the wear resistance of pump components in chemical and industrial operations. But, the stainless steel is in desperate condition to withstand the wear under fatigue loading. Hence, surface modification to attain higher-order wear resistance is a growing trend in research. This study examines the surface modification of a Martensitic Stainless Steel (MSS) alloy by a nickel- and chromium-based Inconel 617 alloy coating applied through three different techniques: Atmospheric Plasma Spray (APS), Tungsten Inert Gas (TIG), and Metal Inert Gas (MIG) cladding techniques. The cladded subsurface microstructure is studied for possible grain structure improvements and defects. The porosity measurement results reveal the rich oxide formation, followed by more micro-pores and microcracks for MIG cladded ones. The effect of coating technique on wear performance of the coating is investigated through statistical modelling to rank the prominent wear resistance coatings associated with the ideal wear parameters. The statistical results declare the excellence in wear resistance of APS coating by registering 84.92% and 51.05% reductions in wear rate than MIG and TIG depositions, respectively. The confirmation experiments are conducted to validate the statistical findings. The post-worn-out surface analysis corroborates the phenomenon of wear being driven by adhesive-initiated two and three-body abrasive wear mechanisms.
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