Tribological characteristics of HVOF sprayed Fe-based composite coatings at elevated temperatures

This study evaluates the tribological performance of Fe-based composite coatings for aerospace and automotive applications, focusing on wear resistance at elevated temperatures. The coatings, comprising 15% WC-Co and Cr 3 C 2 in an SS316L matrix, were deposited onto maraging steel via HVOF spraying. Microstructural analysis and adhesive strength testing confirmed strong particle bonding, with the coatings achieving a hardness of 711 ± 14 HV. Dry sliding wear behaviour was assessed using a ball-on-disc tribometer with alumina as the counterface under 10 N and 30 N loads at 25 °C, 300 °C, and 600 °C. Results indicated a decrease in the coefficient of friction and specific wear rate with increasing load and temperature. At 600 °C, wear rates were reduced by ∼97.56% (10 N) and ∼97.12% (30 N) than uncoated steel. Abrasive wear dominated at room temperature, while adhesive and oxidative wear mechanisms emerged at 600 °C, attributed to protective glaze layer formation.