Tribology and Hot Corrosion Behavior of MCrAlY-Based Multicomponent Coatings Containing Copper

The use of composite coatings containing solid lubricants is widely reported in the literature, in particular thermally sprayed coatings containing silver. However, these coatings are often limited in their maximum operating temperature due to the melting point of silver and due to reactions between the components at temperatures above 500 °C. In this study, a novel coating is proposed, which consists of an MCrAlY-based matrix and the addition of components (Cu, Mo, and BaF2) to improve the wear resistance at elevated temperatures. The coatings were sprayed by high-velocity oxy-fuel, heat-treated at 1040 °C, and tribologically tested at room and elevated temperatures. Raman spectroscopy and scanning electron microscopy were used on worn and unworn regions of the coating to characterize the changes in microstructure caused by wear. The coatings were also exposed to oxidation and hot corrosion conditions to evaluate the resistance to high-temperature environments. The results have shown an improvement in wear rates of the coatings upon heat treatment and the formation of a smooth tribolayer at 300 °C. The as-sprayed coating was able to withstand the attack by molten salts without exposing the substrate, and minor weight gain was observed, indicating that the MCrAlY matrix was effective to protect the coating and the substrate against damages induced by salt penetration.