Carbide Coatings Research Articles

Study on the Microstructure and Performance of the Multi-Field Composite-Assisted Laser Cladding of Nickel-Based Tungsten Carbide Coatings

Improving the hardness and wear resistance of die cutting tools is an important issue in the study of the service life of die cutting equipment. Using laser cladding technology, nickel-based composite coatings with varying BiFeO3 contents were prepared on a 45 steel substrate, because BiFeO3 can have an effect on the dilution rate and microstructure of the sample; morover BiFeO3 is a new type of multiferroic material with certain magneto-electric coupling effects which can be prepared for the study of added magnetic fields. The microstructure and morphology were characterized to determine the optimal BiFeO3 content. Based on the optimal addition of BiFeO3, a comparative analysis was conducted to investigate the effect of different magnetic field strengths under a composite energy field on the microstructure, hardness, and wear resistance of Ni-based WC cladding layers. The results show that the optimal addition of BiFeO3 was 5 wt%. At this concentration, there were no significant porosity defects in the coating, and the dilution rate was appropriate (4.77%). Additionally, the interface bonding strength was also increased. With optimal BiFeO3 addition, stirring with different magnetic field strengths was applied to the cladding layer, and the results show that the aspect ratio of the cladding layer gradually increased with increasing the alternating magnetic field strength. When the magnetic field strength in the composite energy field was 40 mT, the microstructure was fine and uniform, the hardness of the cladding layer reached the highest level, about 925.2 HV1.0, the wear resistance was also the best, the friction coefficient of the cladding layer was about 0.54, and the width of the wear mark was about 0.53 mm.

Oxidation Behaviour of TiC/TiN Coatings Deposited by Chemical Vapor Deposition (CVD): Mechanisms, Structures, and Properties

This review explores the oxidation behavior of Titanium Carbide (TiC) and Titanium Nitride (TiN) coatings deposited by Chemical Vapor Deposition (CVD), with a focus on their industrial applications as wear-resistant coatings for cutting tools. It examines effect of process parameters—such as temperature, pressure, precursor composition, and substrate preparation—on formation and performance of TiC/TiN coatings. The review evaluates the microstructural characteristics of these coatings, including crystal structure, using X-ray diffraction analysis. Also, estimates the mechanical properties such as hardness, wear resistance, and adhesion strength. Additionally, the review covers the thermal stability of TiC/TiN coatings, emphasizing their ability to maintain structural integrity at high temperatures, which is essential for the performance of cutting tools and other industrial components. A major focus is the oxidation behavior of TiC/TiN coatings, including the impact of coating composition, deposition methods, and environmental conditions. The review details oxidation kinetics and mechanisms, revealing various stages of oxidation at different temperatures. It also examines oxide scale morphology and its effect on coating properties. Finally, this review reveals the importance of alloying elements, like silicon, in improving oxidation resistance. Composite coatings such as TiSiN and TiSiCN are shown to offer better high-temperature stability compared to traditional TiN coatings. The effects of coating thickness and the benefits of multilayer coatings for enhanced oxidation resistance are also discussed.

Corrosion measurement of thermally sprayed carbide coatings on stainless steel pipes

The petrochemical industries face a formidable challenge from corrosion, which leads to high maintenance costs and lost production. Traditional corrosion monitoring methods frequently fail to provide accurate and reliable results. As a result, these components must be replaced or repaired promptly to avoid increasing costs and limiting component life, which will reduce operation efficiency. Novel techniques with demands for high surface qualities in the future will be applied to develop alloys with better performance and more diverse applications. This study examines the corrosion resistance of cermet coatings, such as tungsten carbide (WC) and Chromium carbide (Cr3C2), in acidic solution by electrochemical impedance spectroscopy and electrochemical potentiodynamic polarisation. Additionally, utilizing optical microscopy techniques, the microstructural characteristics of coatings were assessed. According to the results of the Tafel polarisation test, Cr3C2 coating exhibited a lower rate of corrosion than other coatings. The Cr3C2 coated, WC coated, and uncoated samples reported corrosion rates of 0.924, 1.122, and 2.599 mmpy respectively. The corrosion resistance of Cr3C2 and WC coatings was increased by 64% and 53%, respectively, in comparison to uncoated specimens. This suggests that the coating maximizes economy, minimizes maintenance costs, extends the structure's lifespan, and reduces down the rate of corrosion.

Microstructure and properties of plasma sprayed NbC-Al2O3 composite coatings

Niobium carbide has received widespread attention due to its high melting point, high strength, high chemical stability and high wear resistance, but the current preparation of niobium carbide coatings using plasma spraying technology suffers from low deposition efficiency, poor fusibility of the composite powders, high porosity, and high defects in the coating microstructure. Therefore, the microstructure and properties of NbC-Al2O3 composite coatings prepared by plasma spraying NbC-Al2O3-SiC composite powder and reactive plasma spraying Nb2O5-SiC-Al composite powder were comparatively investigated in this paper. The reaction mechanism of Nb2O5-SiC-Al composite powder during plasma spraying as well as the mechanism of the formation of coatings were analyzed in detail. The results showed that compared with the ex-situ NbC-Al2O3-SiC coating fabricated by plasma spraying, the in-situ Nb2O5-SiC-Al composite coating prepared by reactive plasma spraying had an obvious layer structure, low porosity (5.8%), high hardness (1141 HV0.1), high toughness (22.94 J/m2), and good scratch resistance properties.

Rare earth-doped ceramic coatings: Analysis of microstructure, mechanical properties, and slurry Erosion resistance using high pressure-high velocity oxy-liquid fuel deposition

The high pressure-high velocity oxy liquid fuel (HP-HVOLF) is a current industry-adopted thermal spraying technique for developing high melting point powder coating over surfaces. In the current manuscript, the rare earth (La2O3/CeO2/Er2O3–0.3 wt%. each) doped and without rare earth doped carbide (WC-10Co-4Cr) coatings have been deployed on stainless steel (SS410) via HP-HVOLF process. The comparison among the properties of the substrate, without rare earth coating and rare earth oxides doped coatings have been characterized by conducting mechanical, microstructural, and slurry jet erosion analysis. The results show that the hardness, modulus of elasticity, and flexural strength of the cermet coating are considerably higher for rare earth-doped coatings than those without rare earth-doped coatings and substrates (SS410). The EDX (energy dispersive X-ray spectroscopy) has recognized the occurrence of different elements on the surface together with rare earth. Moreover, its compounds such as Co3W3C and W2C were inveterate using X-ray diffraction (XRD) measurements. The porosity level of the rare earth doped, and un-doped coatings are obtained to be less than 1 % and≥1 to ≤2 % respectively. Moreover, the rare earth-doped cermet coated surface shows hydrophobic behavior with a maximum water contact angle (WCA) of ≈129.4°. Furthermore, the slurry jet behavior of rare earth doped coating shows high wear resistance as compared to without RE doped coatings, indicating its potential for robust performance under erosive conditions.

Microstructural and mechanical characterization of chromium carbide layers obtained on 100Cr6 and X200Cr12 steels by conversion

Carbides and Nitrides of transition metals are widely used due to their interesting properties. Several deposition methods and techniques can be used to produce carbide and nitride coatings. The choice of how to make the deposit depends on several parameters such as, the conditions of use of these deposits, the thickness to be produced, the adhesion between the substrate the deposit, and the cost. In this work, hard coatings of chromium carbide were produced by a conversion treatment on 100Cr6 and X200Cr12 steels. The conversion treatment consists of electrode position of chromium on the surface of 100Cr6 and X200Cr12 steels followed by diffusion annealing treatment at 1000 and 1100 °C for holding times of 1 and 2 hours. The obtained results show that, for all the conversion treatments carried out in this work, there was formation of chromium carbides layer on the surface of steel. However, it should be noted that the nature of the constituting phases of the formed layer depends on the temperature of the diffusion annealing treatment and the duration at this temperature. It should also be noted that the X-ray diffraction analysis has allowed us to show the existence of chromium oxide in addition to chromium carbides. The microhardness profile and the scratch test show that the X200Cr12 steel sample shows better results.These properties are usually obtained by expensive methods such as PVD, CVD, while we can obtain them by easy and inexpensive methods.

Comparing single-shot damage thresholds of boron carbide and silicon at the European XFEL.

Xray free-electron lasers (XFELs) enable experiments that would have been impractical or impossible at conventional X-ray laser facilities. Indeed, more XFEL facilities are being built and planned, with their aim to deliver larger pulse energies and higher peak brilliance. While seeking to increase the pulse power, it is quintessential to consider the maximum pulse fluence that a grazing-incidence FEL mirror can withstand. To address this issue, several studies were conducted on grazing-incidence damage by soft X-ray FEL pulses at the European XFEL facility. Boron carbide (B4C) coatings on polished silicon substrate were investigated using 1 keV photon energy, similar to the X-ray mirrors currently installed at the soft X-ray beamlines (SASE3). The purpose of this study is to compare the damage threshold of B4C and Si to determine the advantages, tolerance and limits of using B4C coatings.

Study on the Properties of TiC Coating Deposited by Spark Discharge on the Surface of AlFeCoCrNiCu High-Entropy Alloy.

Titanium carbide (TiC) coatings were prepared on the surface of AlFeCoCrNiCu high-entropy alloy blocks using electro-spark deposition (ESD). The microhardness and corrosion resistance of the TiC coatings prepared under different voltage and capacitance process parameters were studied. The research shows that the maximum microhardness of the TiC coating on sample 4 (working voltage of 20 V, working capacitance of 1000 μF) is 844.98 HV, which is 81.5% higher than the microhardness of the substrate. This is because the deposition energy increases with the increase in voltage, and the adhesion and aggregation between the coating and the substrate are enhanced, increasing the hardness of the coating. It is worth noting that excessive deposition energy can increase surface defects and reduce the microhardness of the coating surface. Electrochemical testing analysis shows that the corrosion current density of the TiC coating is the lowest (9.475 × 10-7 ± 0.06 × 10-7), and the coating impedance is the highest (2.502 × 103 Ω·com2). The absolute phase angle value is the highest (about 72°). The above indicates that the TiC coating prepared with a working voltage of 20 V and a working capacitance of 1000 μF has better microhardness and corrosion resistance.

Enhancement of mechanical and thermal properties of diamond particles via vanadium carbide coatings

Vanadium carbide coated diamonds were successfully fabricated by molten salt method. The effect of temperature (from 700 °C to 1000 °C) and molar ratio (carbon:vanadium, from 7:1 to 1:1) on the mechanical and thermal performance of vanadium carbide coatings and coated diamond particles were systematically investigated by SEM, EDS, XRD and XPS. The results showed that, compared with uncoated diamonds, the static compressive strength and oxidation resistance of the coated diamonds increased by 42.27 % and 158.82 °C, respectively. The vanadium carbide coatings were mainly composed of V2C and VC. As the temperature rose, the thickness of the coatings increased and cracks and holes appeared on the surface of the coating under thermal stress. With the increasing of the relative content of vanadium in raw materials, the crystal structure of vanadium carbide coatings changed from microcrystalline structure to reticular structure and the microcrystalline structure vanadium carbide coatings showed better performance.

The influence of particle size and velocity on the wear failure of TiC coated Fe under oil extraction conditions: A molecular dynamics study

The application of titanium carbide (TiC) coatings, renowned for their exceptional tribological properties, holds promise for the research on failure prevention in downhole petroleum machinery. In this study, molecular dynamics was employed to coat TiC layers onto Fe surfaces to enhance wear resistance. The effects of particle size and velocity on the wear and erosion resistance failure of the entire system were investigated through nanoindentation, scratch tests, and particle impact studies. The results indicate that the influence of particle size on the abrasion resistance and erosion resistance of materials is manifested in the load trend and surface atomic morphology. In the plastic damage of materials, an increase in velocity weakens the accumulation of slip faults and rearrangement phenomena among internal atoms, resulting in irregular fluctuations in the load curve. Meanwhile, the high-speed system will dominate the influence on temperature by accelerating atomic motion, leading to different orders of magnitude of wear and high-temperature atoms in impact simulations compared to particle size. This provides significant reference for the study of protective failure of TiC coatings in complex oil machinery service environments.

Impact of Silicon Carbide Coating and Nanotube Diameter on the Antibacterial Properties of Nanostructured Titanium Surfaces.

This study aimed to comprehensively assess the influence of the nanotube diameter and the presence of a silicon carbide (SiC) coating on microbial proliferation on nanostructured titanium surfaces. An experiment used 72 anodized titanium sheets with varying nanotube diameters of 50 and 100 nm. These sheets were divided into four groups: non-coated 50 nm titanium nanotubes, SiC-coated 50 nm titanium nanotubes, non-coated 100 nm titanium nanotubes, and SiC-coated 100 nm titanium nanotubes, totaling 36 samples per group. P. gingivalis and T. denticola reference strains were used to evaluate microbial proliferation. Samples were assessed over 3 and 7 days using fluorescence microscopy with a live/dead viability kit and scanning electron microscopy (SEM). At the 3-day time point, fluorescence and SEM images revealed a lower density of microorganisms in the 50 nm samples than in the 100 nm samples. However, there was a consistently low density of T. denticola across all the groups. Fluorescence images indicated that most bacteria were viable at this time. By the 7th day, there was a decrease in the microorganism density, except for T. denticola in the non-coated samples. Additionally, more dead bacteria were detected at this later time point. These findings suggest that the titanium nanotube diameter and the presence of the SiC coating influenced bacterial proliferation. The results hinted at a potential antibacterial effect on the 50 nm diameter and the coated surfaces. These insights contribute valuable knowledge to dental implantology, paving the way for developing innovative strategies to enhance the antimicrobial properties of dental implant materials and mitigate peri-implant infections.

Improvement of carbon fiber oxidation resistance by thin ceramic coating using silica particles

Carbon fiber-reinforced plastics have become indispensable materials in energy saving and new energy technologies, such as automobiles, wind power generators, and hydrogen tanks for fuel cells. However, the lack of oxidation resistance limits the high-temperature applications of carbon fibers. In this study, we developed a coating technology for carbon fibers to improve their oxidative resistance. Carbon fibers with silicon carbide coatings were obtained by the adsorption of silica colloids on carbon fibers using electro adsorption, followed by heating. The resulting coating has small thickness and strong chemical connections. The thermogravimetric analysis confirmed that the oxidation start temperature of the coated carbon fibers was higher than that of carbon fibers. Moreover, the mechanical properties of the coated carbon fibers were maintained. Therefore, the proposed coating technology can broaden the application of carbon fibers as the alternative to some SiC fiber applications. Further, it is applicable for recycling carbon fibers to increase their value in terms of thermal oxidation stability.

Theoretical design and experimental verification of high-entropy carbide ablative resistant coating

Composition design of high-entropy carbides is a topic of great scientific interest for the hot-end parts in the aerospace field. A novel theoretical method through an inverse composition design route, i.e. initially ensuring the oxide scale with excellent anti-ablation stability, is proposed to improve the ablation resistance of the high-entropy carbide coatings. In this work, the (Hf0.36Zr0.24Ti0.1Sc0.1Y0.1La0.1)C1-δ (HEC) coatings were prepared by the inverse design concept and verified by the ablation resistance experiment. The linear ablation rate of the HEC coatings is −1.45 ​μm/s, only 4.78 % of the pristine HfC coatings after the oxyacetylene ablation at 4.18 ​MW/m2. The HEC possesses higher toughness with a higher Pugh's ratio of 1.55 in comparison with HfC (1.30). The in-situ formed dense (Hf0.36Zr0.24Ti0.1Sc0.1Y0.1La0.1)O2-δ oxide scale during ablation benefits to improve the anti-ablation performance attributed to its high structural adaptability with a lattice constant change not exceeding 0.19 % at 2000–2300 ​°C. The current investigation demonstrates the effectiveness of the inverse theoretical design, providing a novel optimization approach for ablation protection of high-entropy carbide coatings.

Chemical Vapor Deposition of Tantalum Carbide in the TaBr5–CCl4–Cd System

The tantalum carbide coatings were deposited on substrates made of 12Kh18N10T steel, ZhC6 alloy, and molybdenum by reduction of TaBr5 and CCl4 vapors with cadmium vapors at temperatures of 950–1000 K. The average deposition rate of coatings on molybdenum was ~5 μm/h, on ZhC6 alloy was ~6 μm/h, and on 12Kh18N10T steel was ~8 μm/h. The coatings were formed as columnar grains on the substrate surface and as a diffuse layer in the substrate material. The surface layers contained mainly tantalum monocarbide TaCy (y = 0.72–0.86) and a small fraction of tantalum. The coatings on the surface of ZhC6 alloy and 12Kh18N10T steel flaked off with increasing thickness, which was due to different thermal expansion of the coating and substrate, as well as concentration inhomogeneity and phase transitions in the substrate material during coating deposition and during the heating and cooling processes.

Solid lubrication performance of multi-layered V2CTx coatings

MXenes induce excellent wear resistance under solid lubrication due to their distinctive surface chemistry, easy-to-shear ability, and capability to form low-friction and wear-resistant tribofilms. However, beyond the extensively studied Ti3C2Tx, other promising members of the MXene family remain largely underexplored. Therefore, we spray-coated multi-layer vanadium carbide (V2CTx) coatings (thickness ∼10.8 μm) on steel substrates and studied their tribological performance for prolonged times (10,000 cycles) using a reciprocating ball-on-disk tribometer with acting contact pressure of 445 MPa in ambient conditions. Results show that V2CTx-coated substrates demonstrate an 8-fold reduction in friction (COF of 0.11) and a 10-fold wear rate reduction (1.405 × 10−6 mm3 N−1 m−1). High-resolution materials characterization confirmed that the remarkable tribological performance of these coatings can be traced back to the formation of protective films on the substrate (tribofilm) and counterbody (transferfilm) consisting of contact pressure and frictional heat-induced degraded, deformed, exfoliated V2CTx nanosheets, nanocrystalline oxides, and amorphous carbon debris. This work fully elucidates the tribological potential of V2CTx, which is of utmost relevance for designing high-performance lubricating materials. Our work has assessed the performance of multi-layer V2CTx (M2XTx) due to its remarkable thermal stability, low molecular weight, good mechanical properties, and high interlayer spacing, thus serving as an entry point into diverse MXene compositions, including M4X3Tx (V4C3Tx).

Growth and properties of tantalum carbide coatings on graphite by TRD technique

The tantalum carbide-coated graphite material exhibits remarkable chemical stability, corrosion resistance, and heat shock resistance, enabling it to demonstrate excellent stability during the growth of wide bandgap semiconductors. Its application significantly enhances the quality of third-generation semiconductor crystals. Nevertheless, the high cost of this material hinders its widespread utilization in the field of wide bandgap semiconductors. To address this challenge, this study employs the Thermo-reaction deposition and diffusion (TRD) technique to successfully fabricate a tantalum carbide coating on the surface of graphite. Through thermodynamic analysis, this article validate the thermodynamic feasibility of preparing tantalum carbide coatings using the TRD process. To achieve a dense and uniform TaC coating on the graphite surface, we systematically investigate the effects of reducing agent content, reaction temperature, and reaction time on the microstructure of the coating. Experimental research has found that a molar ratio of B4C to Ta2O5 of 1:0.64 optimizes the coating uniformity. Deviations from this ratio, either higher or lower, can lead to coating inhomogeneity or even failure in coating formation. Additionally, this article determine that a reaction temperature range of 1200–1400 °C, coupled with a reaction time not exceeding 6 h, represents the most suitable conditions for preparing TaC coatings on the graphite surface. Finally, to evaluate the practical performance of the coated graphite, this article simulate the corrosive environment encountered during the physical vapor transport method for growing aluminum nitride single crystals. The results demonstrate a significant improvement in the corrosion resistance of the coated graphite. This enhancement is primarily attributed to the formation of a dense TaC coating on the graphite surface, which exhibits remarkable stability at elevated temperatures.

Anodic polarization accelerated titanium carbide coating formation in molten salt

Salt-thermo-carburizing (STC) by simply soaking transition metals in molten CaCl2-CaC2 is an effective method to prepare carbide coatings on metallic substrates. Herein, more efficient anodic carburizing (AC) is demonstrated in the same molten salt via electrochemical oxidation of C22−, which greatly accelerating the growing rate of the carbide coating. Typically, TiC coating was successfully prepared on titanium anode coupled with a graphite cathode. The effect of current density, reaction temperature, and reaction time on the composition, morphology, and structure of the carbide coating was systematically investigated. The results demonstrate that anodic carburizing enables a dense, uniform TiC coating formation with a relatively high rate. The growing kinetics of TiC follows parabolic law for both of AC and STC process, but the rate constant of AC (17.61 μm h-0.5) is much higher than that of STC (5.17 μm h-0.5). It only takes ~0.7 h for the AC process to get a TiC coating with a thickness of 15 μm at 875 °C, but takes >8 h for the STC process. The applied anodic polarization improves the interfacial carbon potential gradient by promoting the C22− oxidation, thereby accelerating the growth rate of TiC coatings.

Effect of thermo-reactive diffusion coatings on microstructure and wear behavior of powder metallurgy steel cutting inserts

In this study, powder metallurgy-produced 1.337 steel (PMS 1.3377) was subjected to boronizing, titanizing, and vanadinizing processes at 950 °C for 2 hours. The influence of boride and carbide coatings formed on the surface of PMS 1.3377 on the microstructure of these steels and their wear behaviors at room temperature and 500 °C were investigated. Characterization of the formed coating layers was carried out through Scanning Electron Microscopy (SEM-EDS), X-ray Diffraction (XRD), microhardness, and wear testing. Wear tests considering the cutting tool turning, milling, and drilling applications of PMS 1.3377 were conducted at room temperature and 500 °C in ambient air with a 10 N load and a 250 m sliding distance against an Al2O3 ball. Metallographic studies showed that coating layers with thicknesses of 98±2.1, 11±0.5, 13.5±0.6 µm and hardness of 2566±125 HV0.1, 2037±104 HV0.1, and 1800±197 were obtained by boronizing, titanizing and vanadinizing processes, respectively. The dominant phase structures in the obtained coatings were determined to be FeB, TiC, and VC for boronizing, titanizing, and vanadinizing, respectively. Due to the high hardness of boride and carbide phases and their ability to form more stable oxide layers during wear, the coated samples exhibited lower friction coefficients and lower wear volume losses. While untreated PMS 1.3377 experienced delamination and oxidation wear mechanisms at room temperature, the wear mechanism at 500 °C transformed into adhesive and oxidation wear. On the other hand, in the coated samples, the wear mechanism was found to occur as adhesive, oxidative, and delamination at both room temperature and 500 °C.

Performance and Formula Optimization of Graphene-Modified Tungsten Carbide Coating to Improve Adaptability to High-Speed Fluid Flow in Wellbore

In order to improve the erosion resistance of steel PDC (Polycrystalline Diamond Compact) bit under high-speed fluid flow conditions underground, it is necessary to develop a high-performance erosion-resistant coating. In this paper, laser cladding was used to prepare the new coating by modifying tungsten carbide with graphene. And the effects of tungsten carbide content and graphene content on the coating performance have been thoroughly studied and analyzed to obtain the optimal covering layer. The research results indicate that, for new coatings, 60% tungsten carbide and 0.3% graphene are the optimal ratios. After adding tungsten carbide, the hardness has significantly improved. However, when the tungsten carbide content further increases more than 30%, the increase in hardness is limited. In addition, when the content of graphene is more than 0.3%, the branched structure becomes thicker. In detail, this is a phenomenon where the segregation of Cr, Si, and W becomes very obvious again, and the segregation of Fe occurs at the Ni enrichment site. The research results contribute to the development and optimization of high-quality erosion-resistant coatings under the high-speed flow conditions in wellbore. These are of great significance for improving the efficiency of oil and gas exploration and development.

Development of fine WC-NiCr powder coatings by optimising HVOF spray parameters

Thermal spray processing parameters need to be optimised to mitigate decarburisation and oxidation of carbide-based coatings that causes unacceptable brittleness. In the present work, a theoretical model was developed to optimise kerosene fuelled high-velocity oxy-fuel (HVOF) flame characteristics and spray parameters for producing high-quality WC-NiCr coatings using finer feedstock of particle size distribution of – 30 + 5 μm. The model suggested an oxygen-to-kerosene ratio of 3.3 and a shorter torch barrel to avoid decarburisation in coatings. In total four parameter sets suggested by the theoretical model were selected to spray the fine-cut powder using a 100 mm long torch barrel. The developed theoretical framework was successful to provide optimised set of HVOF spray parameters to deposit high-quality fine carbide coatings with less decarburisation. Also, the coatings deposited using the optimised set of parameters exhibited the best performance in terms of low porosity, inter-splat cracks, brittleness, as-spray surface roughness, and corrosion resistance. Hence, the optimised parameters can be used to produce a finer as-sprayed finish, thereby demonstrating the potential in reducing grinding efforts.