High Temperature Wear Resistance Research Articles

Combinatorial synthesis of AlNi alloys by low-pressure cold spray deposition and post-laser alloying process

Aluminum-Nickel (AlNi) alloys are of great interest due to their exceptional high-temperature wear and corrosion resistance, making them valuable in transport, energy, and materials processing applications. However, challenges in the production and shaping of these alloys, particularly as thick coatings, remain significant. This study introduces an innovative method for the high-throughput synthesis of AlNi coatings, utilizing a two-step process: low-pressure cold spray deposition followed by laser surface alloying. The combination of these two techniques not only improves the synthesis process but also opens avenues for exploring new material compositions with specific application requirements. This approach holds significant potential for accelerating the development and optimization of advanced coatings and multiphase compounds in applications such as repair and additive manufacturing.Aluminum and nickel powders were co-sprayed to create coatings with controlled compositions ranging from 50Al50Ni to 10Al90Ni (wt%). Subsequent laser treatment induced in-situ alloying and homogenization, resulting in dense, uniform AlNi coatings. The microstructure and chemical composition were characterized using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS), while X-ray Diffraction (XRD) identified the formation of various phases, including Al3Ni and AlNi3 phases. The process demonstrated effective alloying and microstructural homogeneity, with residual alumina present at the surface. Despite the presence of some microstructural defects, such as cracking, this method provides a robust foundation for further refinement and opens new possibilities for tailoring alloy properties through combinatorial cold spray and laser alloying techniques.

Enhancing high-temperature wear resistance of plasma-sprayed NiCrBSi coatings with nanodiamond reinforcement

High-temperature wear causes industrial components to degrade quickly, leading to reduced efficiency, frequent breakdowns, and costly repairs. Thermal spraying is a surface modification technique employed to address these wear issues by shielding the component using protective coatings. In this study, the high-temperature wear behavior of plasma-sprayed NiCrBSi coatings reinforced with Nanodiamond (ND) particles was systematically evaluated. The coatings were reinforced with 1 wt% and 2 wt% ND, and their tribological performance was assessed under varying thermal conditions. Tribological tests were conducted using a ball-on-disk setup at elevated temperatures of 473 K, 673 K, and 873 K for 60 min. The experimental results demonstrated a significant improvement in the wear response and frictional characteristics of the NiCrBSi coatings with the incorporation of ND particles. Specifically, the NiCrBSi coating reinforced with 2 wt% ND exhibited a significantly lower wear volume loss and a reduced coefficient of friction when compared to the pure NiCrBSi coating. At 873 K, the NiCrBSi-2ND coating demonstrated a 64 % reduction in wear volume loss and 85 % decrease in the coefficient of friction, compared to the pure NiCrBSi coating. The incorporation of NDs greatly enhanced the lubrication and hardness of the NiCrBSi-2ND coating as well as improved the adhesion of wear debris to the newly exposed wear track. The high thermal conductivity of NDs enhanced heat transfer to the coatings, facilitating the formation of a protective tribo layer at elevated temperatures, which improved the wear resistance of the NiCrBSi-2ND coating. These findings underscore the potential of ND as a reinforcing agent to significantly enhance the durability and efficiency of NiCrBSi coatings in extreme thermal environments.

High-temperature wear resistance, oxidation resistance and melting loss resistance of plasma cladded Co06–Ni60A composite coating for coppery blast furnace tuyere

High-temperature wear resistance, oxidation resistance and melting loss resistance of plasma cladded Co06–Ni60A composite coating for coppery blast furnace tuyere

High-temperature oxidation resistance and wear properties of functionally graded CrHfNbTaTiN high-entropy nitride coating on Ti alloy

High-entropy nitrides have emerged as promising alternatives to traditional protective coatings due to their excellent comprehensive properties. However, there is still a long-standing technical challenge in the design and manufacture of hard and high-temperature stable high-entropy nitride coatings. This study utilized first-principles calculations to evaluate the thermodynamic stability between high-entropy nitrides and corresponding high-entropy metals, as well as titanium alloy substrates, confirming the rationality of the structural design of the functional gradient high-entropy ceramic coating. Subsequently, a double-glow plasma surface alloying technique were conducted to prepare a CrHfNbTaTiN functional gradient high-entropy ceramic coating on titanium alloy, followed by high-temperature cyclic oxidation experiments and high-temperature ball-on-disk wear tests. The research demonstrates that the gradient composition coating exhibits strong interfacial bonding, with an adhesion strength of around 40 N. It maintains excellent oxidation resistance in environments below 700 °C and displays good high-temperature wear resistance. This study contributes to providing insights and guidance for the further development of high-temperature, high-hardness, and wear-resistant materials.

Enhancing high-temperature wear resistance of cladded Inconel 718 through hybrid of directed energy deposition with ultrasonic nano-crystal surface modification

We present an innovative method for achieving highly durable and finely controllable internal microstructures within cladded 718 layers utilizing a hybrid cladding approach. This process alternates between two methods: laser directed energy deposition in which four layers of Inconel 718 built up using a laser power of 350 W and a scanning speed of 800 mm/min, and ultrasonic nanocrystal surface modification (UNSM), applied to every fourth deposited surface at elevated temperatures of 300 and 600 °C, with a frequency of 20 kHz and an interval of 0.05 mm, respectively. Electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) are used to analyze the effect of grain refinement and concentrated dislocation distribution induced by the hybrid cladding. Through the employment of high temperature UNSM treatment between the cladded Inconel 718 layers, profound grain refinement and dislocation enhancement occur, significantly bolstering the wear resistance of the intermediate layer under high temperature conditions. We conducted thorough analyses, employing finite element analysis and experiments, to investigate the diverse temperature conditions of UNSM treatment and their impact on increasing the affected depth of UNSM treatment. Furthermore, we closely examined the changes in microstructure and mechanical properties within the remelted and UNSM-treated zone of the internal layers. Our study confirms that the high temperature hybrid cladding process, operating below 600 °C, resulted in a 27 % reduction in overall material wear-loss compared to conventional cladding methods. Notably, even in high temperature wear tests ranging from 200 to 800 °C, the proposed method significantly mitigated wear amounts in each case, indicating its potential to enhance the mechanical integrity of various components operating under elevated temperature conditions.

Laser melting deposited a laminated H13/17–4PH heterostructure alloy to achieve strength-ductility synergy and outstanding high-temperature wear resistance

To inhibit the cracking behavior induced by the poor ductility of LMD-ed H13 steel, we have adopted a soft/hard laminated composite strategy to achieve a 17–4PH/H13 heterostructure alloy. Also, the effect of its hard-soft interfacial characteristics on tensile properties and high/room-temperature wear resistance has been studied. The research results show that this laminated alloy mainly comprises two alternately stacked martensite layers with a layer width of 350 µm, including lath martensite (H13) and lath martensite (17–4PH). The lath-like martensite layer possesses a high average microhardness value of over 500 HV, far higher than that of LMD-ed 17–4PH steel. Besides, the laminated alloy shows a high σb (∼1721.59 MPa) with a sufficient δ (∼5.21 %), far higher than that of LMD-ed H13 steel (i.e., σb ∼1701.41 MPa and δ ∼ 1.27 %), which the fracture mode is mixed by ductile and cleavage fracture. The H13/17–4PH laminated alloy has excellent wear resistance at RT comparable to the LMD-ed H13 steel. Interestingly, the H13/17–4PH laminated alloy maintains low friction coefficients and wear rates at 600 ℃. Specifically, its high-temperature wear rate (22.28×10−6 mm3 N−1·m−1) is one-eighth as low as that of LMD-ed H13 steel (157.17×10−6 mm3 N−1·m−1). The above results provide a reference for re-manufacturing die steels in industrial applications of high-temperature wear resistance.

Investigating the microstructure and high-temperature wear resistance of TiAl/WC coating modified via scanning electron beam

In this study, TiAl/WC cladding coatings were modified to improve high-temperature wear resistance by scanning electron beam treatment. Results of the microstructure reveal that the modified coatings are composed of an α2-Ti3Al matrix, with a high density of TiC reinforced phase and Ti3AlC2 MAX phase. At a scanning speed of 6 mm/s, TiAl/WC coating exhibits superior microhardness and high-temperature wear resistance. After the wear test at 800 °C, the minimum wear volume of modified TiAl/WC coating is 0.084 mm3, which is 4.47 times smaller than that of the TC21 substrate. It is mainly attributed to the dense and uniform distribution of hard TiC with a rigid supporting role and Ti3AlC2 MAX phases with a self-lubricating effect. Furthermore, due to the effect of frictional heat, the decomposition of Ti3AlC2 promoted the formation of a dense Al2O3 protective film. The wear mechanism of modified TiAl/WC coatings exhibits a synergistic occurrence of slight adhesive wear, abrasive wear, and oxidative wear. Scanning electron beam technology shows significant potential for extending the service life of the coatings in high-temperature environments.

Microstructure and Mechanical Properties of FeCoCrNiAl + WC Composite Coating Formed by Laser Cladding on H13

To enhance high-temperature wear resistance of H13 steel, laser cladding was used to prepare a high-entropy alloy + carbide composite coating. The microstructure and high-temperature wear resistance of the composite coating were systematically analyzed. The results indicate that the FeCoCrNiAl + WC composite coating had a phase structure of BCC + FCC solid solutions, with a small amount of CFe15.1. The microstructure of the composite coating consisted of columnar and equiaxed grains. The microhardness of the FeCoCrNiAl + WC composite coatings was approximately 3.0–3.4 times that of H13. At wear temperatures of 823 K, compared with H13 steel, the wear volumes of composite coatings with different WC contents were reduced by 73.4%–80.2%. Among these, the FeCoCrNiAl + 10% WC composite coating showed the lowest wear volume. Furthermore, when wear temperatures increased from 623 K to 823 K, compared with H13 steel (108.37%), the increase in the wear volume of the FeCoCrNiAl + 10% WC coating was reduced to 90.82%, which indicates the FeCoCrNiAl + 10% WC coating had better high-temperature wear resistance. The wear mechanisms of the composite coating were abrasive and oxidative wear, while H13 steel exhibited abrasive wear, oxidative wear and fatigue wear.

Microstructure and tribological performance of novel Ni-based alloy cladding with excellent high temperature wear resistance and self-lubrication performance

This paper aims to study the laser cladding of Ni-based alloy coatings with excellent high temperature wear resistance and self-lubrication performance on the surface of parts such that meet complex metallurgical service conditions. The composite alloy powders were formed by adding 3 wt%–11 wt% WS2 and Ti powder to NiCrCoMoBSi alloy powder, and the novel Ni-based alloy samples with high temperature wear resistance and self-lubrication performance were cladded on the surface of Cr28Ni48W5 substrate by laser cladding. The results show that the addition of WS2 and Ti powder had a significant influence on the microstructure evolution and high temperature wear resistance and self-lubrication performance of the samples. The laser cladding coating with 7 wt% WS2 and Ti had the 3 % TiS self-lubricating phase and 19 % enhanced phase with the best microstructure matching relationship, which improved the high temperature wear resistance and self-lubrication performance of the sample. At 800 °C, compared with the Cr28Ni48W5 superalloy substrate, the friction coefficient of the laser cladding coating was 0.22 and the wear ratio was 1.70 × 10−5 mm3 N−1 m−1, which were reduced by 60 % and 54.67 % respectively. The mechanism of the enhanced wear resistance and self-lubrication performance was elaborated.

Improvement of High Temperature Wear Resistance of Laser-Cladding High-Entropy Alloy Coatings: A Review

As a novel type of metal material emerging in recent years, high-entropy alloy boasts properties such as a simplified microstructure, high strength, high hardness and wear resistance. High-entropy alloys can use laser cladding to produce coatings that exhibit excellent metallurgical bonding with the substrate, thereby significantly improvement of the wear resistance of the material surface. In this paper, the research progress on improving the high-temperature wear resistance of high entropy alloy coatings (LC-HEACs) was mainly analyzed based on the effect of some added alloying elements and the presence of hard ceramic phases. Building on this foundation, the study primarily examines the impact of adding elements such as aluminum, titanium, copper, silicon, and molybdenum, along with hard ceramic particles like TiC, WC, and NbC, on the phase structure of coatings, high-temperature mechanisms, and the synergistic interactions between these elements. Additionally, it explores the potential of promising lubricating particles and introduces an innovative, highly efficient additive manufacturing technology known as extreme high-speed laser metal deposition (EHLMD). Finally, this paper summarizes the main difficulties involved in increasing the high-temperature wear resistance of LC-HEACs and some problems worthy of attention in the future development.

Effect of laser remelting treatment on the tribological properties of plasma sprayed WC–Cr3C2–Ni reinforced NiCrBSi coatings

The incorporation of single hard phases, such as tungsten carbide (WC), and chromium carbide (Cr3C2), into NiCrBSi coatings effectively enhances their performance, thereby fulfilling the tough requirements of high-temperature friction condition. To investigate the collaborative reinforcing effect of multiple hard phases and further enhance the high-temperature wear resistance of the coating, a novel WC–Cr3C2–NiCrBSi binary hard phase reinforced coating was developed and subjected to laser remelting treatment. The as-sprayed coatings demonstrate a distinct lamellar structure that diminishes upon remelting, resulting in significant densification of the coatings and a reduction in porosity to 0.3 %. The microhardness of the remelting coatings is reduced by about 10 % due to dilution of the coating by the lower hardness of the base material. However, during the laser remelting process, WC and Cr3C2 decompose and dissolve into the alloying binder phase of the coating, serving as solid solution agents. In cases where the concentration of W elements is elevated, a considerable precipitation of W-rich carbide is observed within the coating. Notably, N30 coatings demonstrate remarkable were resistance at both ambient and 700 °C, resulting in a significant reduction in wear volume by 86.5 % and 55.2 % respectively in comparison to original NiCrBSi coatings. The remelting treatment enhances the densification of the coating, improves the homogeneity of the microstructure, and reduces the coefficient of friction of the coating. The laser-remelted coating exhibits a decreased wear volume, attributed to a transition in its wear mechanism from fatigue-dominated to abrasive wear at room temperature. Conversely, under frictional conditions at 700 °C, the remelted coating experiences an augmented wear volume, attributed to severe abrasive wear.

Comparison of High-Temperature Wear Resistance of Gas-Flame and Ion-Plasma Sealing Coatings with 0.1% Yttrium

Wear-resistant sealing coatings of KNA-82 system with 0.1% yttrium addition for hot parts of gas-turbine engines, applied by gas-flame and ion-plasma methods, are considered. The introduction of yttrium increases the operating temperature from 900°C to 1100°C. The methodology of modeling of processes of contact interaction of engine parts under operating conditions has been developed. Tribotechnical tests modeling the contact of the coating surface with the rotor ridge tops and blade feathers have been carried out, after which linear wear has been measured and the results have been statistically processed. The gas-flame coatings show slower wear reduction at temperatures up to 800°C, while both coatings show similar properties at 1100°C. The improved properties are attributed to the formation of phase-like Ni3Y compound in the grain boundaries.

Surface mechanical rolling treatment-introduced gradient nanostructured Inconel 625 alloy with enhanced high-temperature wear resistance

Heterogeneous gradient nanostructures induced through surface treatment of nickel-based superalloys hold significant promise for enhancing wear resistance. In this study, a 700 µm ultra-thick gradient nanostructured (GNS) strengthening layer was fabricated on the surface of an Inconel 625 alloy plate via surface mechanical rolling treatment (SMRT). Subsequently, the tribological behaviors and wear resistance mechanisms of coarse-grained (CG) and GNS samples at temperatures ranging from 25 ℃ to 800 ℃ were comparatively investigated. The results indicated that the gradient nanostructures significantly enhanced the high-temperature wear resistance of the samples, which wear characterized by low coefficient of friction (COF), wear rate and thin friction layer. This enhancement was attributable to the stability and excellent hot hardness of the gradient nanostructures during friction.

Improving High-Temperature Wear Resistance of Ti–6Al–4V alloy via Si–B–Y Co-Deposited Coatings

Improving High-Temperature Wear Resistance of Ti–6Al–4V alloy via Si–B–Y Co-Deposited Coatings

Investigation of mechanical properties and high temperature wear resistance of CoFeNi1.5VZr0.4Six high entropy alloys optimized by Si alloying

The current work studies the mechanical properties and high-temperature wear resistance of CoFeNi1.5VZr0.4Six high entropy alloys by Si alloying. The Si alloying transforms Ni7Zr2 into a more wear-resistant silicide phase, and the microstructure changes from lamellar eutectic structure to dendritic structure. The high temperature microhardness, compressive strength and fracture toughness of the HEAs increase first and then decrease with the increasing Si content. The Si alloying in HEAs brings about significant improvements in wear resistance at elevated temperature through the combined effects of phase structure modifications and compositional changes in the tribo-layer. The augmented mechanical properties of the worn subsurface layer contribute to improved wear resistance at elevated temperatures.

Microstructure characterization and high-temperature wear mechanism of high-entropy alloy matrix composite coating fabricated by laser cladding

The development of diecasting technology requires hot die steels with high-temperature resistance. In this study, a high-entropy alloy (HEA) was combined with ceramic particles to generate a CoCrFeNiMo0.2Nb0.2/WC composite coating via laser cladding. The coating consisted of a face-centered cubic (FCC) matrix with unmelted WC particles, eutectics and nanoscale (Mo)NbC phases. With the strong lattice distortion caused by the sequestration of W atoms, a nanoscale amorphous layer existed between the Laves and HEA matrix phases. A transition layer with the same structure as the Laves phase was facilitated between the WC particles and the HEA matrix. Due to the hard phases in the HEA matrix and their interfaces, the composite coating with a high proportion of WC exhibited excellent wear resistance under high-temperature dry friction conditions. When the WC was 60 wt%, a minimum wear rate reached to 0.74 × 10−5 mm3/(N·m) at 600 ℃ and 1.46 × 10−5 mm3/(N·m) at 800 ℃. The destruction pattern of the composite coating at 600 ∼ 800 °C was due to the interaction of the adhesive, oxidative and abrasive wear. The composite coatings fabricated in this study provide a route to enhance the high-temperature wear resistance of die-casting molds.

Advanced wear protection at high temperatures: A study of Al20V20Cr20Nb(40-x)Mox RHEA coatings on Ti6Al4V by laser cladding

Al20V20Cr20Nb(40-x)Mox Refractory High Entropy Alloys (RHEAs) coatings were applied to Ti6Al4V surfaces via laser cladding. These coatings, primarily in a single BCC phase with dendritic microstructures, demonstrated varied wear resistance. Notably, the Al20V20Cr20Nb10Mo30 exhibited the highest wear resistance, achieving a wear rate reduction of 98.35 % and 99.28 % compared to uncoated Ti6Al4V and the Al20V20Cr20Nb30Mo10 coating, respectively. This superior performance is attributed to the formation of a dense oxide film and the beneficial presence of rod-like Al2(MoO4)3 and Cr2(MoO4)3 oxides, which enhance mechanical clamping at the surface. The study highlights the critical role of rapid oxide film formation at 600 °C in enhancing the high-temperature wear resistance of Ti6Al4V, offering insights into the tribological behaviour of RHEA coatings under extreme conditions.

Enhancing high-temperature performance of Inconel 718 LDED samples through hybrid laser polishing post-treatment

ABSTRACT A hybrid laser polishing post-treatment was introduced to enhance the surface quality and high-temperature performance of laser directed energy deposition (LDED) Inconel 718 samples. The surface morphology and microstructure were analysed before and after laser polishing, and the result showed that the surface roughness was reduced by 97.4% and the grains of the recrystallized layer were refined through this post-treatment. Furthermore, the wear resistance, corrosion behaviour, and tensile strength of the laser polishing LDED Inconel 718 samples at the high-temperature of 650°C were investigated detailed. The result showed that the high-temperature tensile strength saw an increase of 14.97%, while both the high-temperature wear resistance and corrosion performance of Inconel 718 exhibited improvements compared to the as-fabricated samples.

Mechanical, materials, and physicochemical effects on the high-temperature tribological behaviour of laser additive manufacturing AlCoCrFeNi2.1 eutectic high-entropy alloys

ABSTRACT The AlCoCrFeNi2.1 eutectic high-entropy alloys (EHEAs) were prepared using selective laser melting (SLM) to study the tribological properties at high temperatures, focusing on the complex mechanism of the friction process. The density of the SLM EHEAs is 99.70%. The lamellar and cellular structures are unevenly distributed at different locations. In situ XRD demonstrated the transition from BCC to FCC with increasing temperature. A large number of B2 particles are distributed in the BCC matrix. The fluctuation of the friction coefficient is closely related to the shape and size of the wear debris. The hardness of the alloy is ∼105 HV at 1000 °C. The wear rate first increases and then decreases with increasing temperature. The maximum thickness of the oxide film is 13.52 μm at 1000 °C and exhibits delamination. The combination of mechanical, materials and physicochemical effects during friction contributes to the excellent high temperature wear resistance.

High-temperature wear resistance improvement mechanism of TiAlCrNiSiNbx high-entropy alloy films through sliding wear-induced gradient nanostructure

TiAlCrNiSiNbx high-entropy alloy films (HEFs) with varying Nb concentrations were deposited using multi-target magnetron co-sputtering at a controlled sputtering power. At room temperature (RT), 300 ℃, 500 ℃ and 700 ℃, the average coefficients of friction (COF) and wear rates of TiAlCrNiSNbx HEFs were lower than those of TC4 alloy. TiAlCrNiSiNbx HEF with a Nb content of 12.36 at% exhibited the best wear resistance at 700 ℃. A nanocomposite layer (∼260 nm) and a plastic deformation region (∼1.2 µm) formed on the film during the wear at 700 ℃. The Al2O3, Cr2O3, SiO2, and Nb2O5 in the nanocomposite layer facilitated the formation of a dense oxide layer. The cooperative deformation effect of nanocrystalline metal oxides and amorphous phases is conducive for inhibiting strain localization and enhancing wear resistance. The grain size of the nanocomposite layer was significantly refined, with an average size of 3.98 nm. This was attributed to the grain refinement caused by the interaction of dislocations and deformation twins in the plastic deformation region, which improved the strength and hardness of the film. The gradient nanostructure of the nanocomposite layer and plastic deformation region led to a more homogeneous plastic deformation, effective inhibition of strain localization and suppression of the micro-crack.