Abstract
A growing understanding of wear behavior of various thermally sprayed ceramic–metallic matrix coatings has occurred over recent years. This has resulted from the continuous evolution in spraying methods as well as material feedstock, and the corresponding new aspects of the field that have been thoroughly explored. This paper aims to review recent developments in thermally sprayed tungsten carbide-based coatings, with specific emphasis on evaluating alternative binders, processing routes and tribological behavior of the coatings. A comprehensive evaluation of various compositions as binders for WC-based coatings, considering environmental concerns and market requirements has been carried out. The properties and performance of various potential alternatives for cobalt as a conventional binder for these coatings have been assessed. Moreover, different thermal spray methods have been reviewed, particularly highlighting the role of processing parameters, phase change and feedstock characteristics in the high-velocity oxy-fuel (HVOF) and high-velocity air fuel (HVAF) techniques. A comparison is made between HVAF and HVOF coatings in terms of their performance under different wear environments. Finally, various scenarios of material removal in HVAF and HVOF coatings, under various wear conditions, have also been reviewed.
Highlights
Tungsten carbide (WC)-based metal matrix composite coatings are the most popular materials used as a thermally sprayed wear-resistant layer (Ref 1, 2), thanks to their excellent performance in severe wear environments (Ref [1, 3, 4])
A comprehensive review on thermal spray WC-based coatings has been presented with specific emphasis on alternative binders, processing techniques and tribological behavior of these coatings
While high-velocity oxy-fuel (HVOF) is currently the most widely employed process for applying WC-based coatings, highvelocity air fuel (HVAF) has emerged as a promising technique to tackle some of the shortcomings of the HVOF method such as decarburization
Summary
Tungsten carbide (WC)-based metal matrix composite coatings are the most popular materials used as a thermally sprayed wear-resistant layer (Ref 1, 2), thanks to their excellent performance in severe wear environments (Ref [1, 3, 4]). These coatings consist of two main phases: first, WC grains as a hard phase to resist against wear and, second, a metal matrix that acts as a ductile binder phase to hold the carbide grains together and provide them physical support (Ref 5). A comprehensive review is performed on hardmetal compositions for thermal spray coatings in (Ref 7) discussing various binder chemistries used in their systems. An update on existing potential candidates considering the processing route, mechanical properties and how they perform when comparing to the reference Co binder seems essential
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
