Abstract
Air plasma spraying technology was used to prepare ZrB2–NiCr coatings for the surface protection of gears and improving their service time. The morphology of the coating was investigated by means of scanning electron microscope. The generation of new phases and decomposition of old phases in the powders and coatings were explained by Gibbs free energy calculations. The hardness and wear resistance of the coatings were measured using a Vickers microhardness tester and a ball-on-disk tribometer, respectively. The results showed that ZrB2–NiCr composite coatings present typical thermal spraying morphologies, and mainly contain ZrB2, Ni4B3 and Ni phases. In addition, the coating with an added 20 wt%ZrB2 demonstrated the lowest wear loss and highest hardness (812 HV), which was about five times that of the substrate. The wear process generated some plate-like debris for the 20ZrB2–NiCr composite coating, which suggested the occurrence of adhesive and oxidative wear, while the other coatings also showed signs of adhesive and fatigue wear on observation of the worn surfaces.
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