Studies on air jet erosion behavior of plasma-sprayed Cr2C3 coatings on Al6061 alloy

This study assesses the efficacy of plasma-sprayed Cr 2 C 3 coatings on AA6061 aluminum alloy in reducing erosion at different angles (30, 60, and 90°). The experimental setup involved maintaining a distance of 80 mm between the components, feeding the powder at a rate of 55 g/min, and applying a current density of 460 amps. Weight loss measurements and surface morphology analyses were performed using scanning electron and confocal microscopy. The findings suggest that the Cr 2 C 3 coating significantly improves erosion resistance when compared to specimens without any coating. The erosion angle had a significant impact on the performance of the coating. The coating experienced the least weight loss at an angle of 30° (28.45 g), followed by increased losses at angles of 60° (30.34 g) and 90° (34.2 g). These findings emphasize the significance of the impact angle in determining the severity of material removal. • The study found that the angle of erosion has significant impact on Cr 2 C 3 coatings, excelling at 30° with minimal loss. • Plasma-sprayed Cr 2 C 3 coatings on AA6061 provide superior erosion resistance over untreated. • Efficiency of Cr 2 C 3 coatings depends on standoff distance (80 mm) and powder feed rate (55 g/min). • Plasma spraying current density (460 amps) is crucial for Cr 2 C 3 coating performance.