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<p>AISI H13 steel punches used in hot forging operations are subjected to intense thermal and mechanical loading, leading to degradation mechanisms such as abrasive and adhesive wear, thermal fatigue cracking, plastic deformation, and coating delamination. To enhance tool durability under these severe conditions, this study evaluates the performance of WC-10Co4Cr coatings deposited by high-velocity oxygen fuel (HVOF) spraying, as well as a duplex surface treatment combining plasma nitriding prior to HVOF deposition. The punches were characterized in terms of microstructure, microhardness, and wear mechanisms after industrial forging trials. The duplex-treated punch exhibited a 22% increase in service life compared with the punch coated solely with WC-10Co4Cr, producing 223 additional components before reaching the dimensional tolerance limit. Microstructural and SEM analysis revealed that the nitrided diffusion zone effectively hindered crack propagation into the substrate and improved coating support, delaying delamination and substrate damage. These findings demonstrate the synergistic effect of plasma nitriding and HVOF coating in improving wear resistance and operational reliability of hot forging tools.</p>

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Improvement of wear resistance in AISI H13 hot forging punches through duplex treatment combining plasma nitriding and HVOF coating

  • 期刊论文

  • 发表日期：

    2025年12月10日

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  • Angela Selau Marques,
  • Rafael Luciano Dalcin,
  • Leonardo Fonseca Oliveira,
  • Giovanni Rocha dos Santos,
  • Alexandre da Silva Rocha

摘要

AISI H13 steel punches used in hot forging operations are subjected to intense thermal and mechanical loading, leading to degradation mechanisms such as abrasive and adhesive wear, thermal fatigue cracking, plastic deformation, and coating delamination. To enhance tool durability under these severe conditions, this study evaluates the performance of WC-10Co4Cr coatings deposited by high-velocity oxygen fuel (HVOF) spraying, as well as a duplex surface treatment combining plasma nitriding prior to HVOF deposition. The punches were characterized in terms of microstructure, microhardness, and wear mechanisms after industrial forging trials. The duplex-treated punch exhibited a 22% increase in service life compared with the punch coated solely with WC-10Co4Cr, producing 223 additional components before reaching the dimensional tolerance limit. Microstructural and SEM analysis revealed that the nitrided diffusion zone effectively hindered crack propagation into the substrate and improved coating support, delaying delamination and substrate damage. These findings demonstrate the synergistic effect of plasma nitriding and HVOF coating in improving wear resistance and operational reliability of hot forging tools.