Chromium-nitride in situ composites with a compositional gradient formed by reactive DC plasma spraying

Abstract

Nitrides of transition metals have good wear- and corrosion-resistant properties because of their high hardness and chemical stability. Chromium-nitride coatings can be deposited by ion plating; however, the thin thickness due to the slow deposition rate must be improved for severe wear-resistant applications. The main objective in this paper is to realize good structural control in the processing of chromiumnitride in situ composite coatings formed at a high deposition rate. They were synthesized by reactive low-pressure plasma spraying using elemental chromium powder as a spray material. The transferred arc between the gun electrode and the substrate was used to accelerate the nitriding reaction. The sprayed coatings consist of chromium, Cr2N, and CrN, which have a composition gradient from the substrate interface to the surface. The volume fraction of Cr2N increases with transferred arc current, and nonreacted chromium concurrently decreases, except close to the substrate. The CrN phase, however, only exists as a surface layer of 20 to 30 μm because it is decomposed to Cr2N above 1420 K. The hardness of the composite coatings depends on the volume fraction of Cr2N, and it increases to 1300 HV at a Cr2N volume fraction of 0.98. The seizure stress with lubricant depends on the coating hardness. The maximum seizure stress of 24.9 MPa is obtained at a hardness of 1300 HV. The composite coatings also show a superior wear resistance. Hence, the Cr2N in situ composite coatings synthesized by reactive plasma spraying with transferred arc are expected to be good candidates for wear-resistant applications.