Abstract
Wear-resistant coatings are critical to many industries for extending the life span of components and reducing costs. NiCrBSi coatings are one of the most utilized Ni-base wear-resistant coatings for both ambient and high temperature applications, capable of being applied by both welding and thermal spray processes. If thermal spraying is used to apply NiCrBSi coatings, a modification treatment is often needed to minimize imperfections of the coating layer and improve its properties. Here, use of friction-stir processing (FSP) and furnace re-melting (FR) processing are investigated in terms of their effect on the microstructure and wear properties of a NiCrBSi coating applied on plain carbon steel. Optical and electron microscopy, X-ray diffraction analysis, sliding wear test, and micro-hardness measurements have been used to characterize samples. Based on the results, FSP improved performance versus FR in terms of homogeneity, micro-hardness enhancement, and elimination of defects, leading to more homogeneous coating structures. Also, porosity in the coating layer drastically decreased from 14 % in the as-sprayed condition to 0 % after the FSP process. Additionally, by performing the friction-stir processing, the hardness of the coating increased by 60 % due to a reduction of defects in the layer while breaking down and homogeneously dispersing hard particles in the microstructure.
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