The Wear Resistance of Reinforced Coatings Fabricated by Three Different Processes on High-Density Tungsten Alloy

To address the surface wear issues of tungsten alloys in die-casting mold applications-where low hardness coupled with severe service conditions involving high-pressure impact from molten metal, thermal cycling, and component counter-friction-this study employed three techniques: laser cladding, plasma spraying, and vacuum surface carburization. Three distinct strengthening coatings were prepared on a tungsten heavy alloy (WHA) substrate. X-ray diffraction (XRD), scanning electron microscopy (SEM), a Vickers hardness tester, and block-on-ring friction and wear tests were employed to characterize the phase composition, microstructure, hardness, and wear resistance of the coatings. The results indicate that all three coatings significantly enhanced the hardness of the substrate, albeit through different strengthening mechanisms. The hardness increase in the laser-clad coating is attributed to the combined strengthening effect of rapid solidification-induced fine grains and dispersed WC particles. The enhanced hardness of the plasma-sprayed coating is due to the intrinsic hardness of WC and its dense layered structure. The carburized layer exhibits the highest hardness, resulting from the continuous WC phase formed via in situ reaction and an interface-free gradient transition with the substrate, which eliminates interfacial weak zones. Under loads of 50 N and 100 N, the plasma-sprayed coating demonstrated the best wear resistance, with wear volumes of 0.16% and 0.18% of that of the substrate, and wear depths of 4.57% and 3.50% of that of the substrate, respectively. It also exhibited the optimal load adaptability, making it a preferred solution for surface strengthening of tungsten alloy die-casting molds.