Design and Processing of Hard and Self-Lubricating NiCr/hBN-cBN Composite Coatings by Laser Cladding: Investigation of Microstructure, Hardness, and Wear

Hardness and wear resistance are the requirements of nickel-based superalloys used in gas turbine blades. This study uses laser cladding technology to develop three types of wear-resistant coatings—NiCr-2%hBN, NiCr-12%cBN, and NiCr-2%hBN-12%cBN—on GTD-111 superalloy. The above coatings’ microstructure, microhardness, and tribological behavior were systematically characterized by scanning electron microscope, hardness tester, pin-on-disc wear device, and three-dimensional profiles. The hardness test results showed that the hBN coating has the lowest hardness (692 HV) due to its layered structure, and the hBN-cBN coating has the highest hardness (992 HV) due to its complex structure and the creation of inhomogeneous nucleation centers in the coating. The wear test results showed that the hBN coating has a lower coefficient of friction (COF) (0.49) than the hard cBN coating (0.53) due to its lubricating properties. Meanwhile, the wear rate of the hBN coating is lower than the wear rate of the hard cBN due to the weak forces of one in the B-N bond. However, the wear test results of hBN-cBN coating showed that the effects of hBN and the high hardness of cBN cause the formation of a coating with the lowest wear rate (0.22 × 10−6 mm3/N·m), COF (0.41), fluctuation, wear depth (17.2 µm), and wear volume loss (0.32 × 105 µ3) compared to the other two coatings. In addition, in the hBN-cBN coating, due to the greater driving force for the inhomogeneous nucleation of the melt, a larger area of equiaxed grains was formed, which in turn had a significant effect on increasing the wear resistance.