Abrasive Wear Behavior of Fe-Based Amorphous/Nanocrystalline Coatings Deposited by High-Velocity Oxygen Fuel and Wire Arc Spray

Abrasive wear behavior of high-pressure high-velocity oxygen fuel (HP-HVOF) and wire arc spray (WAS) iron-based coatings were compared. Microstructural analysis of the coatings was carried out by scanning electron microscopy and energy dispersive spectroscopy. X-ray diffraction was also used to characterize the microstructures of the coatings. A PANalytical X'Pert PRO diffractometer using a Cu-Ka radiation source was utilized. The microhardness, porosity, and abrasive wear resistance of the produced coatings were compared. ASTM G65 standard was applied for the coatings' abrasive wear assessment using a dry sand rubber wheel abrasion test rig. The HVOF iron-based coatings showed amorphous structures, whereas the wire arc spray technique yielded polycrystalline coatings. The results show higher resistance to abrasive wear for the HVOF coatings in comparison with WAS coatings justified by the higher microhardness, higher amorphous fractions, and lower porosity induced by the process. The morphologies of the worn surfaces of both coatings demonstrated that a combination of micro-plowing and micro-cutting mechanisms has conducted the whole wear process.