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Abrasive-Erosive Wear of Thermally Sprayed Coatings from Experimental and Commercial Cr3C2-Based Powders

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Abstract

In this paper, high-velocity oxy-fuel sprayed coatings from experimental Cr3C2-Ni powder produced by mechanically activated thermal synthesis and disintegrator milling are compared with coatings from commercial Cr3C2-NiCr powder under room- and elevated-temperature abrasive-erosive wear (AEW) conditions. In a room-temperature AEW test, the coating made from the experimental powder had wear rates that were 1.1-5.3 times higher than the coating from the commercial powder; this difference was the lowest at the highest impact velocity (80 m s−1). Under AEW tests at elevated temperature (300 and 550 °C), the coating made from the experimental powder exhibited wear rates that were 1.2-2.8 times higher in comparison with that made from the commercial powder, but this difference was smaller under an oblique impact angle (30°) and higher temperature conditions. The reasons for the lower resistance against AEW of the coating made from the experimental powder were found to be its lower ability to resist plastic indentation and deformation as well as lower indentation fracture toughness at room temperature, weaker bonding between the matrix and reinforcement and probably lower mechanical properties as well as unfavourable residual stresses at elevated temperatures.

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Acknowledgments

The authors thank Dmitri Goljandin, Ph.D., for his help with the manufacture of the experimental Cr3C2-Ni powder and Deniss Tšernobajev, M.Sc., for his help with the wear tests. This work was supported by the Institutional Research Funding IUT19-29 “Multi-Scale Structured Ceramic-Based Composites for Extreme Applications” of the Estonian Ministry of Education and Research and by the base funding provided to R&D institutions by the Estonian Ministry of Education and Research, Project Number B56, “Innovative Polycrystalline Diamond (PDC) Drag Bit for Soft Ground Tunnel Boring Machines”.

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Authors and Affiliations

  1. Ensto Ensek AS, Paldiski maantee 35/4A, 76606, Keila, Estonia

    Heikki Sarjas

  2. Department of Materials Engineering, Tallinn University of Technology, Ehitajate tee 5, 19086, Tallinn, Estonia

    Andrei Surzhenkov, Kristjan Juhani, Maksim Antonov, Eron Adoberg & Priit Kulu

  3. Centre for Materials Research, Tallinn University of Technology, Ehitajate tee 5, 19086, Tallinn, Estonia

    Mart Viljus & Rainer Traksmaa

  4. Department of Materials Science, Tampere University of Technology, P.O. Box 527, 33101, Tampere, Finland

    Ville Matikainen & Petri Vuoristo

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  1. Heikki Sarjas
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  2. Andrei Surzhenkov
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Correspondence to Andrei Surzhenkov.

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Sarjas, H., Surzhenkov, A., Juhani, K. et al. Abrasive-Erosive Wear of Thermally Sprayed Coatings from Experimental and Commercial Cr3C2-Based Powders. J Therm Spray Tech 26, 2020–2029 (2017). https://doi.org/10.1007/s11666-017-0638-2

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