Effect of tungsten carbide content on the wear performance of plasma-clad nickel-based tungsten carbide coatings

Abstract The performance demands for cutter rings in tunnel excavation have increased, necessitating improved wear and corrosion resistance of their surfaces. Plasma-clad tungsten carbide coatings can significantly enhance these properties. This study is one of the first to systematically investigate the wear performance of plasma-clad nickel-based coatings with specific tungsten carbide (WC) content (50% and 60%) under dry wear conditions, using an in-depth comparative analysis of wear mechanisms. Through experimental design, wear coefficient and volume analysis, and performance evaluation, we investigate the mechanical properties and microstructure of the coatings before and after wear. Techniques such as metallographic analysis, hardness evaluation, scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) were used. Additionally, this study introduces an optimized testing protocol for analyzing wear behavior under varying loads, contributing to a more precise understanding of how WC content impacts wear resistance. Results show that variations in load, tungsten carbide content, and operating conditions impact the coating’s structure and wear performance. The primary wear mechanisms observed were abrasive and adhesive wear. An optimal tungsten carbide content provided superior wear resistance, with a wear coefficient 1.5 times higher and a wear volume half that of coatings with excessive tungsten carbide. These findings offer valuable insights for applying plasma cladding technology to develop high-wear-resistant coatings.