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Corrosion and Wear Analysis of High-Velocity Oxy-Fuel Sprayed WC-10Co-4Cr and Colmonoy-6 Coatings on Nickel-Aluminum Bronze Alloy Substrate

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Abstract

Nickel-aluminum bronze (NAB) alloys are widely used in hydraulic and pumping bodies due to their suitable mechanical properties and corrosion resistance. However, the tribological performance of these materials needs to be improved. In this study, the WC-10Co-4Cr, and Colmonoy-6 coatings were applied on a NAB alloy using high-velocity oxy-fuel (HVOF) spraying technique to enhance the corrosion and wear performance of the NAB substrate. The XRD phase analysis evidenced the dominant presence of the WC and W2C phases in the WC-10Co-4Cr coating and the Ni2Cr3 and Si2B3 compounds in the Colmonoy-6 coating. Morphological and surface analysis showed the formation of the coatings with roughness values of Ra = 4.9 ± 0.9 µm for Colmonoy-6 and Ra = 6.8 ± 1.1 µm for WC-10Co-4Cr coatings. The electrochemical measurement in a 3.5 wt.% NaCl solution revealed that applying WC-10Co-4Cr and Colmonoy-6 HVOF coatings improved the corrosion resistance of the NAB substrate by one order of magnitude. This improvement was more significant for Colmonoy-6 coating due to the presence of electrochemically nobler compounds containing Cr and Ni. Wear measurements obtained by pin-on-disk wear test and morphological analysis of the worn path showed the lowest friction coefficient and highest wear resistance for the WC-10Co-4Cr coating followed by Colmonoy-6 coating. The superior wear performance of the WC-10Co-4Cr coating was attributed to its comprehensive mechanical properties with a Vickers hardness of 1152 ± 25 HV30, while the hardness for Colmonoy-6 and NAB substate was 789 ± 65 and 164 ± 5 HV30, respectively.

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Authors and Affiliations

  1. Department of Materials Engineering, Najafabad Branch, Advanced Materials Research Center, Islamic Azad University, Najafabad, Iran

    Mohsen Moghaddasi & Hassan Bakhtiyari

  2. Department of Chemical and Materials Engineering, Shahrood University of Technology, Shahrood, Iran

    Mansoor Bozorg

  3. School of Engineering, University of British Columbia-Okanagan, 3333 University Way, Kelowna, V1V 1V7, Canada

    Ermia Aghaie

  4. School of Materials Engineering, Purdue University, West Lafayette, IN, USA

    Hamid Torbati-Sarraf

Authors
  1. Mohsen Moghaddasi
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  2. Mansoor Bozorg
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  3. Ermia Aghaie
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  4. Hassan Bakhtiyari
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  5. Hamid Torbati-Sarraf
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Correspondence to Hamid Torbati-Sarraf.

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Moghaddasi, M., Bozorg, M., Aghaie, E. et al. Corrosion and Wear Analysis of High-Velocity Oxy-Fuel Sprayed WC-10Co-4Cr and Colmonoy-6 Coatings on Nickel-Aluminum Bronze Alloy Substrate. J. of Materi Eng and Perform 30, 7564–7576 (2021). https://doi.org/10.1007/s11665-021-05965-0

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