Effect of Layer Thickness on the Practical Adhesion of Borided Monel 400 Alloy

This study presents new results on the practical adhesion behavior of a boride layer formed on Monel 400 alloy, developed using the powder-pack boriding (PPBP) at 1223 K for 2, 4, and 6 h of exposure times, obtaining layer thicknesses from approximately 7.9 to 23.8 µm. The nickel boride layers were characterized using optical microscopy, Berkovich nanoindentation, X-ray diffraction (XRD), and scanning electron microscopy (SEM) to determine microstructure, hardness distribution, and failure mechanisms over the worn tracks. Scratch tests were conducted on the borided Monel 400 alloy according to the ASTM C-1624 standard, applying a progressively increasing normal load from 1 to 85 N using a Rockwell-C diamond indenter, revealing that critical loads (LC1, LC2, and LC3) increased with layer thickness. The tests monitored the coefficient of friction and residual stress in real time. Critical loads were determined based on the correlation between the normal force and visual inspection of the worn surface, identifying cracks (cohesive failure) or detachment (adhesive failure). The results exposed those cohesive failures that appeared as Hertzian cracks, while adhesive failures were chipping and delamination, with critical loads reaching up to 49.0 N for the 6 h borided samples. Also, the results indicated that critical loads increased with greater layer thickness. The boride layer hardness was approximately 12 ± 0.3 GPa, ~4.0 times greater than the substrate, and Young’s modulus reached 268 ± 15 GPa. These findings underscore that PPBP significantly enhances surface mechanical properties, demonstrating the potential for applications demanding high wear resistance and strong layer adhesion.