Frictional wear performance under oil-lubricated conditions and wear resistance mechanism of high-velocity arc-sprayed FeNiCrAl coating

Abstract

To expand the application of Fe-Al intermetallic compounds in abrasion-resistant coatings and improve the room-temperature brittleness of Fe-Al alloys, FeNiCrAl cored wires based on an Fe-Al alloy for high-velocity arc spraying were manufactured in this study. To further study the friction and wear characteristics of the resulting high-velocity arc-sprayed FeNiCrAl coating, a 3Cr13 coating was selected as a comparison material. Friction tests at various loads (20 N, 50 N, and100 N) were conducted using a UMT-3 multifunctional friction and wear tester under oil-lubricated conditions, and an X-ray diffractometer, a hardness tester, a laser scanning microscope, and a scanning electron microscope (SEM) combined with energy-dispersive spectroscopy (EDS) were used to analyze the friction coefficient variations, phase compositions, Vickers hardness, microstructures, and friction surface morphologies of the two coatings. The results indicate that the friction coefficient of the FeNiCrAl coating is less than that of the 3Cr13 coating under the same conditions. The wear rate variation of the FeNiCrAl coating is smaller than that of 3Cr13 as the load increases. The FeNiCrAl coating mainly exhibits plowing wear at low loads; as the load increases, the pressure on the plowing regions extrudes the material and generates slight peeling wear. The FeNiCrAl coating has superior abrasion performance because dense iron oxide, along with both Fe3Al and Al2O3 oxide films, forms on the friction surface. Furthermore, the FeNiCrAl coating has superior hardness, covers the friction surface, and improves the coating abrasion performance.