Process of high temperature synthesis in producing composite carbide powders for thermally sprayed coatings

Abstract

The paper presents the characterization of powders containing hard phases of chromium carbides in a NiCr matrix, intended for thermal spraying coatings. The synthesized composite powder containing hard phases and plastic matrix, produced in high-temperature synthesis with chosen powder metallurgy processes has been presented. Commercial materials, such as NiCr- CrxCy, are fabricated by means of agglomeration and sintering method. Processes of high temperature synthesis of Cr3C2, Cr7C3, Cr23C6 carbides combined with NiCr powder mechanical alloying are presented in the article. Parameters of the carbides synthesis were determined in the reactive -protective atmosphere. In the rotation- vibration mill, processes were conducted using grinding and appropriate mechanical alloying at variable amplitude. The standard and synthesized powders were thermally sprayed by HVOF method in Jet Kote II and Diamond Jet system. The structure and phase composition of the powders and coatings were determined by: light and scanning microscopy, X-ray phase analysis (RTG) and energy dispersive X-ray analysis (EDX). The structure and wear properties of HVOF sprayed coatings containing chromium carbides has been presented. The thermally sprayed coatings are characterized of wear resistance in abrasion and erosion tests. The sprayed coatings characterized high resistance in wear conditions.