Abstract
In this work, a new WC-Cr3C2-CoNi coating was fabricated on steel substrate by thermal spraying the feedstock powder after an alumina-assisted pre-alloying treatment. The Cr3C2 content in the cermet coating was optimized based on the comparison of wear and corrosion properties with the conventional WC-based coating. The results showed that a (Co, Ni)6(W,Cr)6C solid-solution binder phase was formed because of the pre-alloying treatment above the eutectic temperature of feedstock powder. Moreover, sufficient diffusion of various atoms enabled the achievement of complete metallurgical bonding between carbides and the binder phase in the feedstock particles. These featured microstructures were partially retained in the resultant coatings, which thus possessed exceptional wear and corrosion resistance. The performance enhancement mechanisms of the developed coatings were proposed in terms of the unique design in composition and microstructure of the pre-alloyed feedstock powder.
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