Increasing WC Content Research Articles

Mechanical and tribological properties of WC particles reinforced Cu-20Zn matrix composites

Tungsten carbide (WC) particles can be used as reinforcement to improve the mechanical and tribological properties of metal matrix. Herein, WC reinforced Cu-20Zn matrix composites were prepared. The mechanical and tribological properties of composites were also investigated. It was confirmed that the Cu3Zn solid solution was formed during the sintering process. Due to the solid solution and load transfer strengthening mechanism, the tensile and flexural strength were significantly improved. When the WC content was 30 wt%, the tensile and flexural strength were both increased by about two times compared with Cu-20Zn alloy. Additionally, the two-body abrasive and adhesive wear were gradually weakened with increasing WC content. When the WC content was 30 wt%, the composites showed low friction coefficient and wear rate. The formation of tribo-film, which was induced by tribo-oxidation reaction, was conceived to be responsible for the favorable lubricating properties.

“Effect of tungsten carbide (WC) on electrochemical corrosion behavior, hardness, and microstructure of CrFeCoNi high entropy alloy”

High-entropy alloy HEA (CrFeCoNi) was reinforced with variety of weight percentages of 5:20 wt.% WC particles. The alloy samples were mechanically prepared in a ball roll mill for 25 h by 10:1 ball to powder ratio at 180 rpm. Then WC was mixed with the prepared alloys in a high-speed ball mill for 1 h by 350 rpm under a controlled atmosphere. The mixed samples were compacted by a uniaxial press under 700 MPa and then sintered at 1200 °C for 90 min under air atmosphere. The corrosion behavior of the tested samples in 3.5 wt.% NaCl solution was investigated using electrochemical polarization measurements. The microstructure of the sintered samples with high relative density showed three phases, which were FCC matrix, W-rich carbide, and Cr-rich carbide and homogeneously distributed all over the alloy matrix. The hardness of the (CrFeCoNi)1-X (WC)X HEAs was increased gradually with the increasing of WC content from about 336.41 HV up to 632.48 HV at room temperature. The results indicated that the addition of WC improves the corrosion resistance. Especially, the 20 wt.% of WC addition remarkably enhanced the comprehensive corrosion resistance and easy passivation of (CrFeCoNi)1-X(WC)X HEAs. Also, the wear rate of 0 wt.% WC HEA is (1.70E-04) which is approximately 4.5 times higher than the wear rate of 20 wt.% WC HEA (3.81E-05); this means that wear resistance is significantly improved with the increase of WC content.

WC-High Entropy Alloy Reinforced Long Life Self-Grinding Silage Knife Prepared by Laser Cladding.

The working environment of agricultural knives is bad, which makes the knives wear out easily. A wear resistant layer of AlCoCrFeNi high entropy alloy (HEA) reinforced by tungsten carbide (WC) was prepared by laser cladding on one side of the cutting edge of a 65 Mn silage knife. Both the effects of WC addition on the microstructure and mechanical properties of AlCoCrFeNi (WC)x (x = 0, 0.1, 0.2 and 0.3 in mass percentage) alloys were investigated. All experimental alloys displayed a crystalline structure of simple body centered cubic (BCC). The hardness of the cladding layer increases with the increase of WC content, and the hardness value enhances from 740 HV0.2 to 1060 HV0.2. A self-grinding edge was formed during working for the cladded knives. The cutting quality can be improved and the service life of agricultural knives can be increased meanwhile. The weight loss rate of untreated knives was about 2.64 times that of the cladded knives after a 76 h field experiment.

Effect of WC content on laser cladding Ni-based coating on the surface of stainless steel

Ni-based cladding coatings with WC weight percentage of 5%, 7.5% and 10% were prepared on the surface of 0Cr17Ni12Mo2 stainless steel by Raycus RFL-C1000 laser, and optical microscope, scanning electron microscope, energy spectrum analyzer, X-ray diffractometer, microhardness instrument, electrochemical analyzer, friction and wear test machine and wear track measuring instrument were used to characterize the microstructure and properties of the coatings. The results showed that the coating microstructure was mainly composed of cellular crystals and columnar crystals，and due to the combined effects of convection and rapid solidification of laser in the molten pool, WC granules were unevenly distributed and had "agglomeration" effect. With the increase of WC content, the nucleation core in the coatings saw an increase, and the degree of grain refinement raised. In addition, the coatings obtained higher thermodynamic stability and microhardness with the increase of WC content. However, as the number of unevenly distributed WC granules acting as primary batteries added, the tendency of corrosion reaction was enhanced and the corrosion rate increased initially, followed by a decrease. Owing to the influence of solid solution strengthening, dispersion strengthening and surface defects such as cracks and pores, the wear volume and friction coefficient of the coating showed a trend of first growing and then dropping with the increase of WC content.

The effect of WC content on the bonding strength and mechanical properties of WC/Ni60 coatings of brake disc

Laser cladding metal-based ceramic composite coating has significant advantages in improving the surface properties of brake discs. WC powder (5–35%) was mixed into Ni60 powder to prepare different WC/Ni60 composite coatings by laser cladding. The samples were treated by grinding and polishing for further experiments. The effects of WC content on bonding strength, residual stress, fracture toughness, and material strength of cladding coating were studied. At the same time, the fracture morphologies were observed and analyzed by SEM. It was found that the bonding strength of different coatings exceeded 170 MPa. The optimal range of bonding strength was 15–30% WC content. With the increase of WC content, the porosity of the coating increased continuously. When the WC content was 30%, the maximum porosity of the coating was 5.6%. When the content of WC reached 30%, the residual stress of the coating was the largest, but when it exceeded 30%, the residual stress began to decrease. With the increase of WC content, the compression resistance of the coating gradually decreased. The compression resistance maintained a high level, which conformed to the optimal range of bonding strength. When the WC content was less than 35%, the bending strength of the material was improved, which the 25% WC content had the maximum bending strength. The optimal range of bonding strength covered the bending strength. Therefore, when the WC content was 20–30%, which had shown good bonding strength and mechanical properties. In the fracture morphologies, the 20% WC coating was the most smooth, and the bonding strength is the best, which has consistency.

Microstructure and properties of Ni-WC gradient composite coating prepared by laser cladding

In this study, an Ni-based gradient composite coating reinforced with WC was prepared on a Q345R steel substrate by laser cladding. The Ni-WC composite coating was designed as a multilayer structure with gradient composition. The coating started with a layer of C276 alloy with 10 wt% WC on the substrate, and the subsequent layers were composed of Ni60 alloy with different WC contents (10, 30, and 50 wt% WC). The overall morphology, phase composition, and microstructure of the coatings were investigated. The microhardness and the wear properties of each layer of the coatings were also evaluated. The results showed that the gradient composition design was beneficial for reducing the cracking tendency. The coating was composed of an Ni-based matrix, WC, and multiple carbides and borides hard phases. With increasing WC content in the layers, the hard phases exhibited regional distribution characteristics. The WC reinforcement particles underwent different types of dissolution during the cladding process. From the surface to the substrate, the average microhardness of the coating was 1053.5 HV0.2, 963.4 HV0.2, 859.0 HV0.2, 441.7 HV0.2, and 260.5 HV0.2. The wear tests revealed that the coefficient of friction and the wear loss values of the four layers were all lower than those of the substrate, demonstrating enhanced wear resistance.

Effect of WC content on microstructure, hardness, and wear properties of plasma cladded Fe–Cr–C–WC coating

The Q235 sample was coated with ball-milled Fe–Cr–C–WC powder using plasma cladding technology, and the influence of tungsten carbide (WC) content on the surface microstructure, hardness, and wear properties of the coated steel was evaluated. The single factor test of optimal WC content was carried out on DML-02BD plasma cladding machine, and the material after cladding was analyzed. The microstructure distribution, elemental composition and phase composition of the coating were observed by MIRA3-XMH scanning electron microscopy. The microhardness of cladding layer can indirectly reflect the properties of cladding layer to a certain extent, which is measured by the Vickers microhardness tester. The wear quality, friction coefficient and wear mark morphology can directly reflect the wear resistance of the test blocks. These are observed by the ring block friction and wear tester and the ultra depth of field microscope, respectively. With an increasing WC content, the microhardness of the cladding layer shows an upward trend. The main hard phases of the cladding layer after adding WC are (Cr, Fe)7C3, (Fe, Ni)23C7, and the other phases are γ-Fe, Fe3W3C, WCandFe2W. After 6 h friction and wear test, the cladding layer with 30%WC showed the best wear resistance. The total wear amount, wear volume, wear rate and friction coefficient were 0.01 g, 4.22 mm3, 2.344 × 10–4 mm3/(N·m), and 0.35, which were 1/10, 1/5, 1/5, and 7/10 of those without WC cladding layer, respectively. It can be concluded that different WC contents affect the surface microstructure and properties of Fe–Cr–C alloy coating treated by plasma cladding technology. At a WC content of 30%, the microstructure and properties of the cladding layer reach the best.

Correlation between microstructure and mechanical properties of Ti(C,N)-xWC-Ni cermets prepared by mechanical activation and subsequent in situ carbothermal reduction

Herein, Ti(C,N)-based cermets prepared via mechanical activation and subsequent in situ carbothermal reduction was studied. The correlation between microstructural and mechanical performance of these cermets was investigated by X-ray diffraction, scanning electron microscopy, and transmission electron microscopy. Results indicated that with the increase in tungsten carbide (WC) content, hard particles of ceramic gradually evolved from complete solid solution to partial solid solution with a little quantity of core–rim structure. Mean particle size of the cermet first increased, and then, slightly decreased. In addition, grain shape gradually changed from relatively faceted to nearly round. Initially, with the increase in WC content, the increase in transverse rupture strength (TRS) and slight increase in hardness were related to the strengthening of both solid solution and fine grains. However, with further addition of WC, the decrease in hardness was primarily because of lower hardness of (Ti,W,Mo) (C,N) phase with higher W content. Extremely high toughness of cermets with WC content of 0 and 3 wt% was mainly due to the decrease in interface area compared to traditional cermets, which resulted in significant reduction in interfacial strain between the rim and core. Moreover, toughness improvement of cermets containing 6 to 12 wt% of WC was due to comprehensive effect of superb coherent relationship of black core/grey rim particles, semi-coherent relationship with high-density dislocations of solid-solution particles, and solid-solution strengthening of white core-grey rim particles.

Microstructure evolution and properties of a laser cladded Ni-Based WC reinforced composite coating

Abstract Laser cladding Ni-based WC reinforced composite coating was fabricated on the surface of Q235 steel using 6 KW fiber laser. The morphology, composition, microhardness and wear resistance of the composite coating at varied contents of WC particles were studied using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), microhardness tester and a wear tester. The results show that the dilution rate of the cladding layer decreases first and then increases with an increase of WC content. When the WC content is 20 wt.-%, the dilution rate is the smallest. In the process of fiber laser cladding Ni-based WC reinforced composite coating, WC particles partially dissolve and interact with other elements to form eutectics, which exist as lumpy shapes, strips and as spherical shapes. By increasing the WC content, the structure of the cladding layer appears to be refined. The main phases of the laser cladding layer are γ-Ni, M7C3, M23C6, CrB, WC and W2C. As the WC content increases, the hardness of the cladding layer increases. When the WC mass fraction reaches 40 wt.-%, the average hardness of the composite coating can be more than five times the substrate. When the mass fraction of WC is 20 wt.-%, the wear resistance of the cladding layer is best, which is more than three times that of Ni60A coating.

Microstructure evolution and properties of a laser cladded Ni-Based WC reinforced composite coating

Abstract Laser cladding Ni-based WC reinforced composite coating was fabricated on the surface of Q235 steel using 6 KW fiber laser. The morphology, composition, microhardness and wear resistance of the composite coating at varied contents of WC particles were studied using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), microhardness tester and a wear tester. The results show that the dilution rate of the cladding layer decreases first and then increases with an increase of WC content. When the WC content is 20 wt.-%, the dilution rate is the smallest. In the process of fiber laser cladding Ni-based WC reinforced composite coating, WC particles partially dissolve and interact with other elements to form eutectics, which exist as lumpy shapes, strips and as spherical shapes. By increasing the WC content, the structure of the cladding layer appears to be refined. The main phases of the laser cladding layer are γ-Ni, M7C3, M23C6, CrB, WC and W2C. As the WC content increases, the hardness of the cladding layer increases. When the WC mass fraction reaches 40 wt.-%, the average hardness of the composite coating can be more than five times the substrate. When the mass fraction of WC is 20 wt.-%, the wear resistance of the cladding layer is best, which is more than three times that of Ni60A coating.

Reaction Process and Influence of WC Content on Microstructure and Mechanical Properties of Ti(C, N)-Based Cermets

The incorporation of WC promotes the sintering and grain refinement of Ti(C, N)-based cermets, leading to superior mechanical and functional properties. Herein, we present the reaction process of Co–Ti–C–BN–WC system and influence of WC content on microstructure and mechanical properties of Ti(C, N)-based cermets. The results reveal that Ti(C, N) is produced due to the combination of C/TiN or TiN/TiC, whereas TiB2 is formed due to the reaction between B/TiB or Ti/B. Moreover, (W, Ti)(C, N) solid-solution is synthesized due to the reaction of W and C with TiN in the liquid state. In addition, XRD analysis indicates the presence of a small amount of CoW2B2 and Co3C phases with WC content of 15 and 20 mass%. Furthermore, the content of core-ring structure gradually increases with the increase of WC content from 5 to 20 mass%. Also, the grain size increases from 0.364 µm to 0.484 µm with increasing WC content from 5 to 20 mass%. On the other hand, the porosity initially decreases with increasing WC content, followed by a gradual increase. Consequently, the microhardness, fracture toughness and bending strength initially increase with increasing WC content, followed by a decrease. The maximum microhardness, fracture toughness and bending strength are found to be 2010 HV10, 7.21 MPa·m1/2, and 725 MPa, respectively.

Microstructure and properties of Inconel 625 + WC composite coatings prepared by laser cladding

Inconel 625 + WC composite coatings were prepared on the surface of 2Cr13 steel by laser cladding. The microstructure, microhardness and corrosion resistance of the composite coatings with different WC contents were investigated in detail. The results show that the phase compositions of the composite coatings are mainly γ-(Ni, Fe) and various carbides. The content of WC has a significant effect on the microstructure of the cladding layers. When the WC content is 10 wt% and 15 wt%, the cladding layer has developed columnar dendrites. However, the 20 wt% WC coating is mainly composed of cellular dendrites and columnar dendrites. With the increase in WC content, the average hardness of the composite coating gradually increases. The average hardness of 20 wt% WC coating is the highest (HV1 536.98), which is a factor of 2.64 greater than that of the 2Cr13 steel matrix. Electrochemical results show that all the composite coatings have better corrosion resistance than 2Cr13 steel in 0.5 mol·L−1 HCl solution. The composite coating with 10 wt% WC has the best corrosion resistance, its corrosion potential (Ecorr) is 0.78806 V higher than that of 2Cr13 steel, and the corrosion current density (Icorr) is only 0.86% that of 2Cr13 steel.

Influence of additives and concentration of WC nanoparticles on properties of WC−Cu composite prepared by electroplating

Abstract The effects of additives (polyethylene glycol (PEG), sodium dodecyl sulfate (SDS)) and WC nano-powder on the microstructure, relative density, hardness and electrical conductivity of electroplated WC−Cu composite were investigated. The preparation mechanism was also studied. The microstructure of samples was analyzed by XRD, SEM, EDS, TEM and HRTEM. The synergistic effect of PEG and SDS made the WC−Cu composite more compact during the electroplating process. The hardness of WC−Cu composites increased with the increase in WC content, while the electrical conductivity decreased with the increase in WC content. The density of samples tended to increase initially and then decreased with increase in the additive content. When the electroplating solution contained 10 g/L WC nano- powder, 0.2 g/L PEG and 0.1 g/L SDS, the WC−Cu composite exhibited hardness of HV 221 and electric conductivity of 53.7 MS/m. Therefore, the results suggest that WC−Cu composite with excellent properties can be obtained by optimizing the content of additives and WC particles.

On the microstructure-dependency of mechanical properties and failure of low-pressure cold-sprayed tungsten carbide-nickel metal matrix composite coatings

This study improves upon understanding of the effects of reinforcing particle content and microstructure on the mechanical properties and failure of low-pressure cold spray fabricated tungsten carbide-nickel (WC-Ni) metal matrix composite (MMC) coatings. Image analyses were performed on scanning electron microscope (SEM) micrographs of the coatings to characterize the microstructure and measure the total interfacial area between the reinforcing WC particles and the Ni metal matrix, the mean free path between the particles, the average particle size, and the porosity of the coating. Uni-axial quasi-static tensile testing was conducted on the as-sprayed coatings. The tensile stresses that were measured were coupled with the evolving strains that were calculated by using the digital image correlation (DIC) technique. The results showed that mechanical properties, namely tensile strength and Young's modulus, of the composite coatings increased with increasing WC content in the coatings. The increases were due to the refined microstructural features that occurred with the decrease in the porosity of the coating that was caused by significant consolidation of the Ni metal matrix. Furthermore, this increase in strength and Young's modulus was also related to the increase in the interfacial area between the reinforcing carbide particles and the metal matrix that was caused by the increase in carbide content in the coating, a decrease in the average size of the carbides in the coating, and a reduction of the mean free path between the carbide particles. A framework was presented to elicit the micro-macro relationships between the microstructure and the tensile strength of the cold-sprayed composite coatings. Based on the developed framework, two distinct coating mechanical strength regimes were observed, indicating a significant increase in the tensile strength of the coatings that were comprised of more than 30 wt% WC due to the refined microstructure of the coatings. The higher value tensile strength regime was also confirmed by the larger average mechanical energy absorbed to failure under tensile loading and lower damage accumulation. This collection of data of mechanical properties and the microstructures presented in this study are important to validate numerical-based failure models for cold-sprayed composite coatings. Altogether, the results of this study will enhance understanding of the sensitivity of mechanical response of a composite coating to microstructural changes.

Effect of WC content on microstructures and mechanical properties of FeCoCrNi high-entropy alloy/WC composite coatings by plasma cladding

FeCoCrNi high-entropy alloy/WC composite coatings were fabricated via plasma cladding on steels adding different mass fraction of WC. Effects of WC content on the microstructure and mechanical properties of the coatings were studied. The results showed that WC content significantly affected microstructure and the wear resistance of the coatings. With the increase of WC content, the microstructures of the coatings became complex. When WC content was more than 60%, the coatings consisted of WC, FCC phase of HEA matrix as metal bond, Fe3W3C carbide phase and Cr-rich secondary solid solution phase. The Fe3W3C carbides improved the hardness and wear resistance of the coating. When WC content was at a high proportion of 60%, the HEA/WC coating had the best wear resistance with the minimum volume wear rate of 3.27 × 10−7 mm3/N·m and the high hardness of 59.6 HRC, which was better than commercial Ni60/WC coating with the same WC content.

Characterization and corrosion resistance of ultra-high molecular weight polyethylene composite coatings reinforced with tungsten carbide particles in hydrochloric acid medium

Abstract Ultra-high molecular weight polyethylene (UHMWPE) composite coatings reinforced with different concentrations (1, 3, 6, and 9 wt%) of submicron tungsten carbide (WC) particles were synthesized using electrostatic sprayed method, characterized and evaluated for corrosion resistance in 1 m HCl electrolytic solution. Results showed that the mechanical properties and adhesion strength of the coatings improved with the increasing WC content to an optimum loading of 6 wt%. These properties slightly dropped when the WC content was further increased to 9 wt% due to agglomeration of the WC particles. Furthermore, both the potentiodynamic polarization test and electrochemical impedance spectroscopy measurement confirmed the high corrosion protection efficiency of the UHMWPE/WC composite coatings over the pristine UHMWPE coating to a minimum of 80% improvement. The 1 wt% WC reinforced UHMWPE coating exhibited the highest corrosion resistance due to better dispersion of the WC particles in the matrix.

Ionic-liquid lubrication of a nickel-based coating reinforced with tungsten carbide particles

Trihexyltetradecylphosphonium bis(2-ethylhexyl)phosphate ([P6,6,6,14][BEHP]) and trihexyltetradecylphosphonium bis(trifluoromethylsulfonyl)imide ([P6,6,6,14][NTf2]) ionic liquids were used as neat lubricants in nickel-based coatings reinforced with spherical WC particles (sizes: −106 + 45 μm). Three different coatings with 0, 3.3, and 12.4 wt% of WC on the surfaces were tested. Reciprocating tribological tests were performed (load: 100 N, frequency: 25 Hz, stroke length: 4 mm, for 60 min at room temperature). The wear was not related to the WC content for [P6,6,6,14][BEHP]. However, the wear decreased with the increase in WC content when [P6,6,6,14][NTf2] was used. [P6,6,6,14][BEHP] exhibited a better tribological behaviour than [P6,6,6,14][NTf2], particularly in the coating without WC, owing to the formation of a CrO3 protective layer. Compared with [P6,6,6,14][NTf2], [P6,6,6,14][BEHP] slightly worsened the antifriction and antiwear behaviour of the coatings with the decrease in WC content.

Effect of WC addition and cooling rate on microstructure, magnetic and mechanical properties of Ti(C0.6,N0.4)-WC-Mo-Ni cermets

Ti(C0.6,N0.4)-8Mo-xWC-25Ni (x = 0, 3, 6 and 9 wt%) cermets were synthesized under different cooling rates by vacuum sintering. The influence of WC addition and cooling rate on microstructure, magnetic and mechanical properties of the as-prepared Ti(C,N)-based cermets was investigated by using X-ray diffraction (XRD), scanning electron microscopy (SEM), vibrating sample magnetometer (VSM) and physical property measurement system (PPMS). The results revealed that the grain size of the Ti(C,N)-based cermets became finer with WC addition. Furthermore, room-temperature saturation magnetization (Ms), remanence (Mr) and Curie temperature (Tc) of the Ti(C,N)-based cermets initially decreased with increasing WC content, followed by a gradual increase. Cermets bacame paramagnetic at x = 6 under the cooling rate of 2 °C/min, x = 6 and 9 under the cooling rate 35 °C/min, respectively. The decrease in magnetic properties could be ascribed to the enhanced solid solubility of alloy elements in Ni-based binder phase. Moreover, the hardness and transverse rupture strength (TRS) of the Ti(C,N)-based cermets initially increased and followed by a gradual decrease, whereas the fracture toughness initially decreased followed by an increase with increasing WC content. At the same value of x, the Ti(C,N)-based cermets exhibited better magnetic and mechanical properties at the cooling rate of 35 °C/min than that at the cooling rate of 2 °C/min, which could be attributed to the grain refinement strengthening and solid-solution strengthening of the binder phase.

Effect of WC content on the microstructure and mechanical properties of Ti(C,N)-based cermets fabricated by in situ carbothermal reduction of TiO2

The effect of WC content on the microstructure and mechanical properties of Ti(C,N)-based cermets fabricated by in situ carbothermal reduction of TiO2 was investigated using XRD, SEM, TEM, and EDX. After sintering, the final microstructure of the cermets prepared via this novel method was mainly characterized by white core/gray rim grains and black core/gray rim grains, and the morphology of the ceramic grains was different from that in traditional cermets. It was found that WC directly participated in the formation of white cores, thus the volume fraction of grains with white cores increased as the content of WC increased, while the volume fraction of the grains with black cores decreased with increasing WC content. Moreover, the interfaces between the binder phase and rims outside the white cores were rough, whereas the interfaces between the binder phase and rims outside the black cores were smooth and an orientation relationship of (200)R//(111‾)B with a perfectly coherent boundary between them. The average grain sizes of the cermets decreased as the content of WC increased, especially when the WC content exceeded 8 wt%. In addition, macropores appeared in the cermets as the WC content exceeded 12 wt%. Overall, the microstructure of the cermets with 8 wt% WC content was the most homogeneous and densest. The transverse rupture strength, hardness and fracture toughness all initially increased and then decreased as the WC content increased.

Effect of WC addition on microstructure and tribological properties of bimodal aluminum composite coatings fabricated by laser surface alloying

Successful deposition of aluminum composite coatings has been achieved by scanning the laser beam over the 304 stainless steel substrate using a mixed powder of AlSiTiNi and WC. The effects of different WC contents on the microstructure and properties of the bimodal composite coatings were investigated. The friction and wear behaviors of the laser-deposited composite coatings were evaluated using a pin-on-disc testing machine by sliding against tungsten carbide balls at room temperature with a load of 100 N, linear sliding speed of 0.031 m/s, sliding radius of 3 mm and a total sliding distance of 56.5 m. Prior to the wear test, the surface of the coating was ground and polished. For the coating with 20% WC content (wt.%), it possesses high microhardness and wear resistance as well as low coefficient of friction owing to its bimodal microstructure. The coatings are mainly composed of equiaxed crystal in the fully melted region and net structure in the partially melted region, while the partially melted particles are embedded in the fully melted region. In addition, the partially melted region is expanded to further enhance the properties of the coatings with the addition of WC. The phases of FeAl, FeNi, Al5Cr and WC are found in the coatings. The microhardness of the coating with 20% WC is 4.4 times that of the substrate. With the increase of WC content, the maximum coefficient of friction of the coatings is increased. The coating with 20% WC possesses the lowest wear rate, which mainly involves abrasive wear when sliding against the tungsten carbide ceramic counterpart.