Wear Resistance Of Coatings Research Articles

Enhanced corrosion resistance of epoxy coatings through the incorporation of modified TiO2 and reduced graphene oxide

Anti-corrosion coatings ensure material safety and extend service life, serving as important safeguards in the fields of construction, infrastructure, petrochemicals, and marine engineering. Therefore, this study introduces a dual-nanofiller synergistic system by blending epoxy resin, 3-hydroxy-2-naphthylhydrazine modified reduced graphene oxide, and TiO2 nanofillers modified with the silane coupling agent KH570 to create a novel nanocomposite coating. Compared to traditional coatings, the synergistic effect of the dual nanofillers formed a dense nanonetwork structure, enhancing the corrosion resistance and mechanical properties of the coating. The results show that the composite coating has a smooth surface with minimal crack formation. In addition, the toughness and wear resistance of the composite coatings were improved. Electrochemical Impedance Spectroscopy analysis revealed that the impedance value of the Dual nanofiller composite coating was two orders of magnitude higher than that of the other coatings, showing the strongest corrosion resistance. A 45-d long-term immersion experiment was conducted on the composite coatings. The results showed that after 45 d of immersion in 3.5 wt% NaCl solution at room temperature, the Z modulus of the dual nanofiller composite coating decreased from 109 Ω·cm2 to 107 Ω·cm2. Although the performance declined, the coating still exhibited relatively high corrosion resistance and no significant physical defects, maintaining a good overall structure. This study provides an ideal method for enhancing the corrosion resistance of coatings by using a dual-nanofiller synergistic system.

Wear Resistance of N-Doped CoCrFeNiMn High Entropy Alloy Coating on the Ti-6Al-4V Alloy

Wear Resistance of N-Doped CoCrFeNiMn High Entropy Alloy Coating on the Ti-6Al-4V Alloy

Evaluation of Wear Resistance in Tungsten-Doped Diamond-like Carbon Coatings (WC/C) on Coated and Uncoated Surfaces Under Starved Oil Lubrication with R452A Refrigerant

This article assesses the potential of using a diamond-like carbon coating doped with tungsten, a-C:H:W (WC/C), on the sliding pairs of refrigeration compressors. The ability of WC/C coating to provide low wear and a low coefficient of friction was experimentally verified in a specific refrigeration compressor operating environment (lubrication with oil diluted with refrigerant) and under extreme operating conditions (starved lubrication with a small amount of oil). Conditions of starved lubrication with a substance of reduced lubricity promote a temperature increase and high mechanical (friction) stresses on the surface of the sliding pairs. These situations can hinder the effective operation of WC/C coatings. Comparative wear tests were carried out for S235JR steel samples with and without WC/C coating. It was found that the samples with the WC/C coating had the lowest wear values and the lowest friction coefficients (approximately 0.06). A low coefficient of friction suggests that even a small amount of oil (one drop) is likely sufficient to achieve mixed lubrication conditions between the tested sliding surfaces and reduce material loss. The tested WC/C coating can protect sliding friction pairs in refrigeration compressors under extreme operating conditions caused by a lack of oil. Less friction reduces the need for energy to drive the refrigeration compressor. Additionally, the significance of this research is highlighted by the fact that the wear tests were conducted using R452A, a novel, eco-friendly refrigerant.

Effect of Electrofriction Treatment on Microstructure, Corrosion Resistance and Wear Resistance of Cladding Coatings

In recent years, the issue of increasing the wear resistance of the working bodies of agricultural machinery designed for cutting and breaking the soil has received special attention. The surface layers of working bodies of agricultural machinery during operation are subjected to intensive abrasive wear, which leads to rapid wear of equipment and a reduction in its service life. The induction cladding method using materials such as Sormait-1 is widely used to increase the wear resistance of tool working surfaces. However, after coating, additional heat treatment is required to improve the physical and mechanical properties of the material and increase its durability. In electrofriction technology (EFT) hardening, the surfaces of the parts are subjected to melting under the influence of electric arcs. In this work, three types of surface treatment of L53 steel have been investigated: induction cladding using Sormait-1, electrofriction treatment, and a combination of induction cladding followed by electrofriction treatment. The microstructure was analyzed using optical microscopy and scanning electron microscopy. Erosion and abrasion tests were carried out in accordance with ASTM G65 and ASTM G76-04 international standards to evaluate the wear resistance of the materials under mechanical stress. A dendritic structure was formed after the induction cladding of the Sormait-1 material, but subsequent electrofriction treatment resulted in a reduction of this dendritic structure, which contributed to an increase in the hardness of the material. However, the highest hardness, reaching 965 HV, was recorded after electrofriction treatment of L53 steel. This is explained by needle martensite in the structure, which is formed as a result of quenching. Further, the influence of structural characteristics and hardness on erosion and abrasion wear resistance was examined. The analysis showed that the material microstructure and hardness have a decisive influence on the improvement of wear resistance, especially under conditions of intensive erosion and abrasive friction.

Optimized strategy for induction cladding of diamond/Ni-based wear-resistant coatings

Diamond/Ni-based wear-resistant coatings were fabricated on 45 steel using induction cladding, followed by laser remelting of the gradient coatings. The microstructure, phase composition, hardness, and friction properties of the coatings were examined. Results revealed that the surfaces of the composite and gradient coatings primarily consisted of a hard γ-Ni matrix and phases such as diamond, Cr7C3, and Cr23C6. High-temperature diffusion results in a strong metallurgical bond between the coating and the substrate. The gradient coating design significantly reduce the physical property mismatch between the 45 steel substrate and the composite coating. While laser remelting increased chromium aggregation and achieved a more uniform distribution of Fe, Ni, and Si. XRD analysis indicated that the Ni2Si diffraction peaks disappeared. Concurrently, the surface roughness and wear loss of the coating decreased, while the microhardness of the surface layer increased to 1030.74 HV, enhancing surface wear and corrosion resistance performance.

Simultaneous improvement of wear and corrosion resistance of microarc oxidation coatings on ZK61 Mg alloy by doping with ZrO2 nanoparticles

Simultaneous improvement of wear and corrosion resistance of microarc oxidation coatings on ZK61 Mg alloy by doping with ZrO2 nanoparticles

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.

Wear-resistant and stable low-friction nanodiamond composite superhard coatings against Al2O3 counter-body in dry condition

Conventional machining lubricants pose environmental hazards and increase production costs. This study addresses this challenge by investigating nanodiamond composite (NDC) coatings deposited on WC–Co substrates as a lubricant-free alternative for sustainable machining. The NDC films show superior hardness (65 GPa) compared to the substrate (22 GPa) and enhanced adhesion (HF2). The NDC's unique self-lubrication results in a low and stable friction coefficient (COF ≤ 0.095) and exceptional wear resistance (7.45 × 10−8 mm3/N·m) in dry tesing against Al2O3 counter-body. Compared to CVD diamond, NDC coatings show a 47.8 % reduction in COF and a 31.65 % enhancement in wear resistance, promoting environmentally friendly machining practices.

Obtaining wear-resistant coatings by surfacing with powder core welding wire

Obtaining wear-resistant coatings by surfacing with powder core welding wire

Synthesis of high-entropy Ti-Zr-Nb-Hf-Ta carbides and carbonitrides in high-speed arc discharge plasma jet

The interest in high-entropy materials has increased rapidly in recent decades due to their applications in various fields such as environmental barrier coatings, superhard and wear resistant coatings, nuclear energy, batteries, catalysts, thermoelectrics, supercapacitors, biocompatible structures, and microelectronics. In the present work, comprehensive theoretical and experimental studies are carried out to discover a new way to prepare high-entropy ceramic nanopowders of carbides and carbonitrides of IV-V transition metals. The possibility of (TiZrNbHfTa)CxNy formation is investigated using both ab initio and machine learning approaches. The chosen single-stage plasma dynamic technique allowed us to synthesize high-entropy carbide TiZrNbHfTaC5 and the corresponding carbonitrides (N up to 8 wt%) in the form of single-crystalline nanoparticles. By varying the experimental system conditions, we demonstrate not only the production of pure powders, but also the ability to apply different precursors, including pure metals and their oxides. The presented technique provides a simple and universal way to produce high-entropy nanomaterials and opens the door to the synthesis of many functional ceramic powders composed of other carbonitrides with selective nitrogen content.

Effect of Current Density on the Wear Resistance of Ceramic Coatings Formed on 7075 Aluminum Alloy via Microarc Oxidation

Effect of Current Density on the Wear Resistance of Ceramic Coatings Formed on 7075 Aluminum Alloy via Microarc Oxidation

Tribological and Corrosion Properties of Al2O3@Y2O3-Reinforced Ni60A Composite Coatings Deposited Using Laser Cladding

Since rare earth oxides and hard ceramic particles improve coating quality, a novel Al2O3@Y2O3 core–shell structure was prepared. Then, Ni60A coatings with different amounts (2~6 wt.%) of Al2O3@Y2O3 core–shell structures were prepared using laser cladding technology on an H13 steel surface. To demonstrate the unique effect of the core–shell structure on the performance of the coatings, a set of controlled experiments was also conducted with different proportions of Al2O3-Y2O3 mechanically mixed powders. The effect of Al2O3@Y2O3 addition on the phase composition, element distribution, microstructure, wear, and corrosion resistance of the coatings was characterized and tested thoroughly. By comparing the forming quality, hardness, wear, and corrosion resistance of the different coatings, 2 wt.% was confirmed as the optimal concentration of Al2O3@Y2O3, and its corresponding friction coefficient was about 0.44. The wear rate was approximately 4.15 × 10−3 mm3·(N·m)−1, the self-corrosion potential was around −0.3659 V, and the self-corrosion current density was about 1.248 × 10−6 A·cm−2.

Influence of ultrasonic assistance on the microstructure and friction properties of laser cladded Ni60/WC composite coatings

The effects of different ultrasonic vibration powers on the distribution, phase structure, friction and wear properties of WC reinforced particles in laser melted Ni60/WC composite coatings are investigated. The effects of ultrasonic vibration on the microstructure, elemental distribution, crystal orientation, friction and wear properties of the fused coatings are analyzed. The experimental results show that the deposition of WC particles in the lower and middle parts of the coating is significantly improved after the introduction of ultrasonic vibration during the fusion cladding process. In particular, at 600 W ultrasonic power, not only the distribution uniformity of tungsten carbide particles in the coating is optimal, but also the composite coating shows better wear resistance. However, too much ultrasonic power increases the possibility of particle agglomeration. In addition, although the phase pattern of the coating does not change after ultrasonic vibration, the width of the columnar crystalline region of the coating is reduced, and the coating is covered by a homogeneous lamellar nanoscale eutectic structure with the phase compositions of the γ-(Fe, Ni) and M23C6 phases. The ultrasonic vibration improves elemental segregation of the coating, reduces the large number of precipitated phases in the coating, weakens the grain growth orientation, and relieves the local stress concentration in the coating. In addition, the mechanism of the influence of WC particles on the microstructure evolution and wear resistance of the composite coatings is discussed.

Influence of Titanium-Coated Diamond Content on the Microstructure and Wear Resistance of Ni60A Laser Cladding Coatings

Influence of Titanium-Coated Diamond Content on the Microstructure and Wear Resistance of Ni60A Laser Cladding Coatings

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.

Analysis of Erosion of Surfaces in Falling Particle Concentrating Solar Power

Abstract Next generation concentrating solar power (CSP) systems, which utilize solid particles for energy capture, transport, and storage, offer prospects for higher temperature operation, improved efficiency, and reduced overall costs. Nevertheless, the continuous impingement of particles on component materials can result in substantial erosion, significantly constraining the performance and longevity of the components. A comprehensive understanding of particle erosion on surfaces is essential for designing components and operational parameters or coatings that minimize wear. This study presents a computational physics-based particle tracking model of the erosion rate of incident surfaces under different geometric, operational, and particle parameters. The computational model is validated with experimental measurements conducted as part of the study. Computational simulations are presented to elucidate the effects of each parameter and further used to investigate erosion rates in a systematic design of experiments covering a wide range of parameters. Based on the simulation results, a generalized analytical model is developed to relate erosion wear to pertinent dimensionless groups governing the physics of the process. The analytical model is shown to be accurate to within 10% and its use in understanding surface erosion as well as designing wear-resistant coatings to limit erosion within acceptable values is presented.

Research on laser brazing diamond coating process based on temperature field finite element simulation and machine learning

The temperature of laser brazing diamond seriously affects the quality and service life of diamond tools. In this study, a finite element model of laser brazing diamond was established to achieve digital control of the temperature field during the brazing process. It was determined that the main energy of diamond warming comes from the heat conduction of the molten pool. The maximum temperature value within the brazing layer was proposed as an important indicator of the quality of diamond coating formation. The correlation and local sensitivity of each process parameter to the maximum value of temperature were calculated by a neural network-based machine learning method, and the influence of process parameters on the temperature field was explored. The result of the theoretical analys was finally verified by the coating wear-resistance experiments, and the wear-resistance of the diamond coatings was significantly better than that of other cases when the maximum temperature value in the brazing process was in the range of 1100 °C–1130 °C.

Study on the effect of TiC/B on the performance of laser cladding in-situ fabricating wear-resistant self-lubricating coatings

To improve the wear resistance of IN718, coatings containing the self-lubricating phase h-BN were prepared and the coating properties were analyzed in relation to the variation of laser power. The results show the TiC added to the cladding powder partially decomposes and in-situ fabricates new reinforcing phases TiN, B4C, etc. The lubricating phase h-BN was in-situ fabricated by adding B into the powder. As the laser power increased from 1.6 kW to 2 kW and 2.5 kW, eutectic microstructures of high melting point reinforcing and lubricating phases were observed. Due to the decomposition of TiC and in-situ fabricated of TiC2, TiN and B4C concentrations changing with the laser power, the surface hardness of the coatings prepared at 2.5 kW was the highest at 391.03HV0.5. Which is 1.096 and 1.108 times of 1.6 kW and 2 kW. At room temperature, the coating fabricated by 2 kW has the highest average friction coefficient of 0.537. This is because the self-lubricating phase h-BN is a high-temperature lubricating phase and the wear surface has a low oxide content, and is influenced by the hardness of the coating. At 500°C, the coating fabricated with 2.5 kW has the lowest average friction coefficient due to the best synergistic effect of the lubricating and reinforcing phases at 0.376. The 2.5 kW coating has the best wear resistance, with wear rates 0.69 and 0.54 times at room temperature and 0.82 and 0.8 times at 500°C of 1.6 kW and 2 kW. The wear mechanism at room temperature is abrasive wear, and at 500°C is mainly a combination of h-BN and oxide synergistic lubrication.

Microstructure and Wear Resistance of FeCrV15 Coatings by Laser Cladding

Improving the surface performance and service life of 60Si2Mn steel is an important issue in agricultural machinery. A FeCrV15 coating layer may exhibit excellent performance in wear resistance. This research focuses on studying the microstructure and wear resistance of the FeCrV15 coating layer at various scanning speeds through laser cladding. Microstructure, phase distribution, surface hardness, and wear resistance of the coating layers are analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM), a microhardness tester, and laser confocal microscopy. The results indicate that the FeCrV15 alloy coating consists of γ-Fe, V8C7, and Cr7C3. The microhardness of the FeCrV15 coatings increases with the increase in the scanning speed. At a scanning speed of 8 mm/s, the highest microhardness reaches 727.5 ± 27 HV, approximately 2.5 times higher than the substrate. The friction and wear test of the coating is conducted using a 4 mm diameter Si3N4 ball grinding pair. The coatings prepared at different scanning speeds exhibit lower average coefficients of friction and wear rates compared to the substrate. Both the average coefficient of friction and wear rate decrease with increasing scanning speed. At a scanning speed of 8 mm/s, the lowest average coefficient of friction and the lowest wear rate were observed. The main wear mechanisms of the coating are oxidative wear and adhesive wear, with a small amount of abrasive wear.

The effect of annealing on the microstructure and wear performance of laser-clad high-entropy alloy composite coatings for monorail crane braking systems

Laser cladding was utilized to fabricate WC ceramic particle-reinforced CoCrFeMnNi high-entropy alloy (HEA) composite coatings, with an investigation into the influence of annealing heat treatment on the microstructure and wear behavior of the composite coatings. The HEA composite coatings with a WC particle content of 30 wt% primarily consist of a face-centered cubic (FCC) solid solution phase, various M6C carbides with blocky, fishbone, and dendritic morphologies, and incompletely melted WC ceramic particles. The microstructure of the composite coatings remains stable up to a temperature of 570°C. After annealing at 600°C, the microstructure transforms into a typical dendritic morphology with rod-like carbides precipitating from the solid solution and discontinuously distributed in the interdendritic regions. Due to the annealing softening effect, the microhardness of the coating decreases from 488.1 HV0.3 to 443.1 HV0.3. Following annealing at a high temperature of 800°C, recrystallization leads to a refined equiaxed grain microstructure, with precipitated carbides continuously distributed along the grain boundaries, forming a network. The combined effects of precipitation hardening and fine grain strengthening result in an increase in the microhardness of the coating to 568.6 HV0.3 after annealing at 800°C. As the annealing temperature increases, the wear rate of the WC particle-reinforced CoCrFeMnNi HEA composite coatings also increase. The wear mechanism for the unannealed coating is oxidative wear, and the reduction in hardness leads to adhesive phenomena in the coating after annealing at 600°C. The network of carbides reduces the ductility of the HEA and also the toughness of the oxide film, resulting in the highest wear rate for the coating annealed at 800°C, reaching 38.636×10−6 mm3/(N·m). This study provides valuable insights for the fabrication of advanced wear-resistant coatings.