WC-Co Coatings Research Articles

Study on interface bonding mechanisms for high-velocity oxygen-fuel spraying of WC-12Co coatings on AZ31B magnesium alloy

Study on interface bonding mechanisms for high-velocity oxygen-fuel spraying of WC-12Co coatings on AZ31B magnesium alloy

A comparison of cold spray, atmospheric plasma spray and high velocity oxy fuel processes for WC-Co coatings deposition through LCA and LCCA

In this study, an environmental and economic assessment of WC-Co coatings deposited by Cold Gas Spray (CGS), Atmospheric Plasma Spray (APS) and High Velocity Oxy Fuel (HVOF) spray technologies is carried out. Using SimaPro LCA software, several environmental impact categories are analyzed to compare their environmental performance. The economic analysis includes capital and operating expenditures. The results have highlighted that all three processes exhibit low environmental impact in terms of CO2 emissions but the performance of the CGS process is heavily influenced by the low deformability of WC-Co, while the APS process is affected by high electricity consumption. In terms of economic analysis, the HVOF process exhibits the best performance, while the CGS process requires most time to deposit the coating, and consequently, it is the process where the workforce component is most significant. These results depend on the fact that CGS might not be the most suitable deposition technique for fabricating WC-Co coatings.

Mathematical modelling and validation of the mechanical properties of HVOF-sprayed WC-12Co coatings considering the phase composition and defects generated at different process parameters

The thermal spraying process involves many machine-based parameters or independent variables (fuel flow rate, oxygen flow rate, powder feed rate, stand-off distance and many others in the HVOF process). Any combination of these parameters produces only two measurable responses, namely, particle temperature and particle velocity. In this current work, first, the machine-based spray parameters are varied in specific ways to produce different particle temperatures at near-constant velocities and vice-versa. This approach has reduced the number of independent variables to only two. These two factors further influence the in-flight particle reactions, thereby affecting the phase composition and the microstructural defects in the as-sprayed coatings. The X-ray diffraction patterns of the as-sprayed coatings revealed the presence of W2C, W, Co3W9C4, and amorphous Co-W-C phases apart from the WC phase. The W2C and W originated owing to the decarburization of the WC phase. On the other hand, the dissolution of the carbide in molten binder led to the formation of Co3W9C4 and the amorphous Co-W-C phase. The nano-hardness of both the carbide and binder phases increased with an increase in particle temperature owing to a higher degree of decarburization and carbide dissolution respectively. The porosity was the most significant micro-structural defect present in the as-sprayed coatings. An increase in either particle temperature or velocity reduced the porosity present in the as-sprayed coatings. The mechanical properties (microhardness, elastic modulus and indentation fracture toughness) tend to improve as porosity decreases. A comprehensive mathematical model was proposed to predict the mechanical properties of as-sprayed coatings as a function of composition and defects. Finally, the process maps of mechanical properties were plotted in temperature-velocity space.

Microstructure and Cavitation Erosion Performance of Cold-Sprayed WC-12Co and WC-17Co Coatings on Hydraulic Turbine Steels

Microstructure and Cavitation Erosion Performance of Cold-Sprayed WC-12Co and WC-17Co Coatings on Hydraulic Turbine Steels

DEPOSITION BEHAVIOR OF WC-17Co COLD-SPRAYED COMPOSITE COATING ON HYDRO TURBINE STEELS

Cold spraying is a promising technique for depositing wear-resistant coatings on components like hydroturbine steels. This paper highlights the feasibility of hard WC-17Co coating on 13Cr4Ni hydroturbine steel. The coating was deposited at 25, 30, and 40 bar at 800∘C and 50 bar at 900∘C. Further, different characterization techniques (SEM, XRD) were used to analyze the developed coatings. The Vicker hardness testing was employed to determine the hardness of the coated sample. It was observed that WC-17Co coatings deposited at 40 bar and 800∘C offered a maximum hardness of up to 275 Hv, which is an excellent quality for anti-wear applications in hydro turbine blades.

Effect of Laser Power on Microstructure and Properties of WC-12Co Composite Coatings Deposited by Laser-Based Directed Energy Deposition.

During the laser-based directed energy deposition (DED-LB) processing, a WC-12Co composite coating with high hardness and strong wear resistance was successfully prepared on a 316L stainless steel substrate by adopting a high-precision coaxial powder feeding system using a spherical WC-12Co composite powder, which showed a large number of dendritic carbides and herringbone planar crystals on the substrate-binding interface. The influences of laser power on microstructural and mechanical properties (e.g., hardness, friction resistance) of WC-12Co composite surfaces were investigated. The results show that laser power has a significant effect on determining the degree of Co phase melting around the WC particles and the adhesion strength between the matrix and the coating. Lower laser power does not meet the melting requirements of WC particles, thus weakening the molding quality of the composite coating. At high laser power, it is possible to dissolve the WC particles and melt the metal powder between the particles, thus improving the material properties. The laser power increased from 700 W to 1000 W and the average hardness of the coating surface gradually increased from 1166.33 HV to 1395.70 HV, which is about 4-5 times higher than the average hardness of the substrate (about 281.76 HV). In addition, the coatings deposited at 1000 W showed better wear resistance. This work shows that the processing parameters during laser-directed energy deposition can be optimized to prepare WC-12Co composite coatings with excellent mechanical properties.

Decarburization control and performance enhancement: Optimizing HVOF sprayed submicron WC-12Co coating with additives

This study explored enhancing WC-12Co coatings' performance and preventing decarburization by adding Cr, Cr3C2, and VC. Coatings were prepared using HVOF technology, and their microstructure, mechanical properties, wear behavior, and corrosion resistance were analyzed. Results indicated that VC and Cr3C2 add-ins effectively prevented decarburization, with T2 coatings (WC-12Co-2VC-2Cr3C2) showing lower porosity, higher hardness, and improved wear resistance. However, T1 coatings (WC-12Co-2VC-2Cr) demonstrated superior corrosion resistance due to Cr addition. The findings provide insights into the additives' effects on WC-12Co coatings and underscore the potential of VC and Cr3C2 as decarburization inhibitors.

Effect of binder phases on the microstructure and sliding wear properties of HVOF-sprayed WC-based coatings

This study aimed to evaluate the microstructure and wear properties of WC-10Co-4Cr, WC-12Co, and WC-17Co coatings on TC4 titanium alloy. The coatings were deposited using high velocity oxygen-fuel (HVOF) technique. To analyze the influence of binder phases, the coatings were thoroughly examined using scanning electron microscopy, X-ray diffractometer, microhardness tester, and friction and wear tester. The analysis of the results reveals that the primary phases in all three coatings consist mainly of WC, with smaller quantities of W2C and amorphous phases present. The WC-10Co-4Cr powder demonstrates a relatively even particle size distribution, high degree of sphericity, and rough porous surface, allowing for efficient heat absorption and uniform heat distribution, resulting in a dense coating. Notably, the WC-10Co-4Cr coating exhibits significantly smaller tungsten carbide grain size compared to the other coatings. Moreover, the microhardness of the WC-10Co-4Cr coating, measured at 1377.8 HV0.05, is significantly higher than that of the WC-12Co and WC-17Co coatings, which measured at 1258.8 HV0.05 and 1182.4 HV0.05, respectively. Additionally, the WC-10Co-4Cr coating demonstrates low friction coefficient and wear volume, indicating excellent wear resistance. Subsequently, a comprehensive analysis was conducted to determine the reasons for the relative enhancement in binder performance.

Enhanced Adherence, Brittleness, Corrosion, and Sliding Wear by Adding NiCrFeBSiC-Mo on WC-Co Coatings and Hardened Substrates

Enhanced Adherence, Brittleness, Corrosion, and Sliding Wear by Adding NiCrFeBSiC-Mo on WC-Co Coatings and Hardened Substrates

Investigation of the Corrosion and Tribological Properties of WC-Co Tools Hardened with PVD Coatings in Solid Oak Wood Processing

Corrosion and friction coefficient tests were performed on solid oak wood machined with hard-metal woodworking tools coated with PVD coatings (AlCrN, AlTiN, TiAlN, TiCN and CrN). The tannic acid attacks the carbide more intensively than the PVD coatings. During cutting, corrosion spreads on the cutting edge of the cutter due to mechanical action, which dissolves the cobalt binder of the hard-metal and causes the carbide grains to flake off. After 80 min of contact with the wood, the cobalt content decreases from 3.53 to 1.74%. Depending on the PVD coating material, cracks of 4 to 40 µm in width appear after 120 min (9000 m cutting path). After 120 min of machining, wear, corrosion effects and the influence of corrosion on the coefficients of friction were evaluated for tools with and without PVD coatings. TiCN is the most sensitive to corrosion, while AlCrN and CrN coatings are the least sensitive, with the AlTiN coating being the most affected under real cutting conditions (with mechanical + thermal + corrosion effects) and the tools with CrN and AlCrN coatings being the least affected. Corrosion affects the hard-metal and PVD coatings and reduces the coefficient of friction. The angle between the directions of sliding and sharpening of the cutting edge sharpening significantly influences this parameter. The coefficient of friction of hard-metal WC-Co and PVD coatings is higher in the parallel machining direction than in the perpendicular machining direction and ranges from 16.03% (WC-Co) to 44.8% (AlTiN). The coefficient of friction of hard-metal WC-Co decreases by 5.13% before and after exposure to tannic acid, while the corrosion of PVD coatings reduces it by 4.13% (CrN) to 26.7% (TiAlN).

Role of carbide grit size and in-flight particle parameters on the microstructure, phases, and nanoscale properties of HVOF sprayed WC-12Co coatings

Effects of particle temperature and velocity on crystallinity and phase composition of WC-Co coating are successfully decoupled. The effect of grit size on the dissolution and decarburization process is established analytically. The nanostructured coatings were found to be less crystalline than their conventional counterpart for similar in-flight parameters. The cooling rate and the degree of carbide dissolution in the binder phase govern the crystallinity of the as-sprayed coatings. An increase in either of these factors results in a higher degree of amorphization of as-sprayed coatings. The phases present in the coating were quantified, and correlated with particle temperature and velocity independently. The degree of decarburization increased with an increase in particle temperature. The calculated change in Gibbs free energy justified these observations. The effect of particle velocity on crystallinity or phase composition was not significant. The nano hardness of the carbide grits was increased with particle temperature owing to the formation of a hard W2C phase. Similarly, the dissolution of carbides in the binder and the formation of the Co3W9C4 phase increased the binder hardness. The energy analysis revealed brittleness of the binder matrix increased significantly with deposition temperature owing to the formation of the Co3W9C4 phase.

Comparison of Microwave Versus Conventional Furnace Heat Treatments of Carbide Composite Thermal Spray Coatings

Thermal spraying has become an industrial standard in the production of wear-resistant WC-Co and Cr3C2-NiCr composite coatings. However, generating optimum wear-resistant nano-reinforced carbide microstructures within the coatings remains challenging. The alternative two-step approach in this work involves coating formation under high energy conditions to generate maximum carbide dissolution, followed by heat treatment to precipitate nanocarbides. Microwave heating of particulate materials has been reported to offer several benefits over conventional furnace heating, including faster heating rates, internal rather than external heating, and acceleration of reactions/phase transformations at lower temperatures. This novel work explored the use of microwaves for heat treatment (as distinct from melting) of WC-Co and Cr3C2-NiCr thermal spray coatings and contrasted the rate of phase development with that from conventional furnace treatment. Coatings were successfully microwave heat-treated to generate the same phase composition as furnace treatment. Both treatments generated comparable results in the Cr3C2-NiCr system. The WC-Co system achieved a much more crystalline structure in a dramatically shorter time relative to the conventional furnace-treated sample. The results are contrasted as a function of material and microstructure interaction with microwaves and the critical phase transition temperatures to account for the observed responses.

Comparative study of anti-corrosion properties in different CrN/WC-Co duplex coatings processed by PVD/HVOF

WC-Co coatings produced by high-velocity oxy-fuel (HVOF) show the high porosity which limits their application in seawater. Herein, we prepared CrN/WC-12Co and CrN/WC-10Co-4Cr duplex coatings combined with the physical vapor deposition (PVD) and HVOF technologies. The microstructure and the corrosion behavior were studied and compared with WC-Co coatings. The CrN film covers the pores on the surface of WC-Co coatings which enhances the corrosion resistance. In addition, the corrosion products of WC-10Co-4Cr coating seal the defects in the CrN film, and further improve the corrosion resistance of the duplex coatings. The CrN/WC-Co duplex coatings enhance the corrosion resistance of WC-Co coatings, especially for CrN/WC-10Co-4Cr, which greatly increases the corrosion potential and reduces the corrosion current density of WC-Co coatings.

A Comparative Study of the Life Cycle Inventory of Thermally Sprayed WC-12Co Coatings

In this research, a life cycle inventory (LCI) is developed for tungsten carbide–cobalt (WC-Co) coatings deposited via atmospheric plasma spray (APS), high-velocity oxy-fuel (HVOF), and cold gas spray (CGS) techniques. For the APS process, a mixture of Ar/H2 was used, while the HVOF process was fueled by H2. The carrier gas for CGS was N2. This study aims to determine and quantify the inputs (consumption of inputs and materials) and outputs (emissions to air, soil, water, and waste generation) that could be used in the life cycle analysis (LCA) of these processes. The dataset produced will allow users to estimate the environmental impacts of these processes using WC-Co feedstock powder. To obtain a complete and detailed LCI, measurements of electrical energy, gas, WC-CO powder, and alumina powder consumption were performed (the use of alumina was for sandblasting). Furthermore, emissions like carbon dioxide (CO2), carbon monoxide (CO), and noise were also measured. This practice allowed us to determine the input/output process quantities. For the first time, it was possible to obtain LCI data for the APS, HVOF, and CGS deposition processes using WC-12Co as a feedstock powder, allowing access to the LCI data to a broader audience. Comparisons were made between APS, HVOF, and CGS processes in terms of consumption and emissions. It was determined that the APS process consumes more electrical energy and that its deposition efficiency is higher than the other processes, while the HVOF process consumes a large amount of H2, which makes the process costlier. CGS has comparatively low electricity consumption, high N2 consumption, and low deposition efficiency. The APS, HVOF, and CGS processes analyzed in this study do not emit CO, and CO2 emissions are negligible.

Characteristic Analysis and Coating Application of the Innovative HVOF System Based on the Digital Model

In view of the poor working conditions, high cost and time-consuming parameter design of the traditional spray process, an innovative HVOF thermal spray system based on the digital model has been established by this study to improve coating performance and optimize scheme design rapidly. In particular, the digital model of the oxygen/kerosene HVOF spray system is designed on the AMESim multidisciplinary simulation platform for the first time, and the engineering prototype has been successfully developed. Thus, an efficient design method based on the digital model was proposed, according to which the spray control parameters such as oxygen and kerosene flow are obtained conveniently under a combustion chamber pressure of 1.0 MPa and 2.0 MPa, respectively. The error between the simulation and experiment results was generally less than 5%, and the dynamic characteristics of the key components in the actual spray system were well predicted, suggesting that the dynamic response time of the system would generally less than 0.7 s. Additionally, the WC-12Co coatings were deposited under the working conditions of W1.0 and W2.0, respectively, the microhardness of the coating increased about 23% and the corresponding volume wear rate decreased about 18%. The results show that the increase of the pressure of the combustion chamber can further improve the coating performance, which also verifies the feasibility and reliability of the design method. It was concluded that the innovative HVOF system based on the digital model is of great theoretical value and application significance for predicting spray process parameters conveniently and providing excellent coating performance.

Influence of nano-sized WC addition on the microstructure, residual stress, and tribological properties of WC-Co HVAF-sprayed coatings

It has recently been proposed to modify conventional WC-Co coatings with nano-sized particles to improve their properties. Modification of the coatings with nano-sized carbides may provide higher wear resistance or phase composition stability. This work characterized the changes in the residual stresses induced by introducing WC nanoparticles into a WC-Co coating and the resulting change in their sliding wear behavior.A powder mixture consisting of agglomerated and sintered WC-17Co feedstock powder and 5 % nano-sized WC was deposited on a carbon steel substrate using the High Velocity Air Fuel (HVAF) process. Microstructural characterization using scanning electron microscopy and EBSD confirmed that nano-sized WC particles were embedded in the coatings after the spraying process, primarily along the boundaries of the WC-Co lamellae. This resulted in an enhancement of microhardness, indentation fracture toughness, and dry sliding wear resistance, evaluated via ball-on-disk tests against Al2O3 counterparts. Residual stresses in the coatings were also measured by XRD using the sin2ψ method. The normal stress along the torch movement direction decreased significantly when nano-sized WC was added. The addition of nanoparticles also caused a slight decrease in the normal stress perpendicular to the torch movement.

Effect of Different Post Processing Techniques on Microstructure and Mechanical Properties of Atmospheric Plasma Sprayed WC-17Co Coatings

Effect of Different Post Processing Techniques on Microstructure and Mechanical Properties of Atmospheric Plasma Sprayed WC-17Co Coatings

Corrosion Behavior and Mechanism of WC-12Co Coating in Salt Spray Environment

Corrosion Behavior and Mechanism of WC-12Co Coating in Salt Spray Environment

The effect of WC-12Co and CrC-NiCr hard coatings applied by HVOF method on the microstructure, mechanical, and surface properties of steel

In today’s world, the use of metals is widespread across various industries, with St37 steel plying a significant role. However, over time, this metal undergoes significant deterioration in its mechanical and physical properties, mainly due to factors such as corrosion and wear. Rather than using expensive methods such as alloying to extend the life of the metal, a more economical and practical approach is to focus on improving the surface properties. Surface engineering techniques, particularly thermal spraying, offer a viable solution. Among thermal spray techniques, High Velocity Oxygen Fuel (HVOF) spraying stands out as an economical and time-saving method for producing materials, equipment or machine components with high resistance to damage mechanisms such as corrosion, erosion and wear. This study investigates the application of tungsten carbide and chromium carbide-nickel chromium coatings to St37 steel surfaces using the HVOF method. Microhardness measurements were carried out after coating to evaluate the mechanical properties, while scratch and wear tests were carried out to determine the tribological properties. In addition, X-ray diffraction (XRD) and scanning electron microscopy (SEM) were used to assess the structural characteristics of the samples. The results indicate the formation of phases such as Cr3C2, NiCr and W2C on the low-alloy steel surface after the tungsten carbide and chromium carbide-nickel-chromium coating processes. Coating thicknesses of 204 and 239 µm were achieved for tungsten carbide and chromium carbide-nickel-chromium, respectively. These coatings contributed to improved mechanical and tribological properties. The WC-12Co coated sample exhibited the highest hardness value (1304 HV0.1), while the CrC-NiCr coated sample recorded the highest critical load value in the scratch test (48 N). The WC-12Co coated samples showed the best wear resistance.

SLURRY EROSION PERFORMANCE OF COLD SPRAYED WC-12Co COMPOSITE COATINGS

In the current investigation, a cold sprayed WC-12Co (WC- Tungsten Carbide, Co- Cobalt) composite coating was deposited on CA6NM steel. Further, microstructural analysis was carried out by using Scanning Electron Microscopy (SEM)/Energy Dispersive Spectroscopy (EDS) and X-Ray Diffraction (XRD) characterization techniques. Mechanical characterization was carried out to measure microhardness, bond strength and surface roughness. The value of coating hardness and surface roughness was measured to be 270 ± 15 Hv and 2.12 ± 0.5 [Formula: see text]m. Thereafter, slurry erosion test was performed under accelerated conditions and performance of coated samples was compared under different parameters such as erodent size, impact velocity, angle of impingement and slurry concentration. WC-12Co coatings show no phase transformation or de-carburization of the WC-Co particles as observed in other thermal spray techniques. The WC-12Co coatings was proved to have beneficial erosion reduction rate as compared to untreated CA6NM steel. The slurry erosion performance of coated samples was improved by 68%. SEM images of degraded coatings show the brittle characteristic of WC-12Co coatings.