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<p>The application of NiCr-Cr<sub>3</sub>C<sub>2</sub> coatings in high-temperature tribo-corrosive environments is significantly limited by the incompatible oxidation response and pronounced electrochemical mismatch between the carbides and the NiCr matrix. In this work, NiCr-Cr<sub>3</sub>C<sub>2</sub> and CoCrFeNiMo-Cr<sub>3</sub>C<sub>2</sub> composite coatings were fabricated via supersonic flame spraying. In comparison to NiCr-based composite coatings, the CoCrFeNiMo high-entropy alloy (HEA) based composite coating exhibits a lower coefficient of friction, enhanced frictional stability, and superior corrosion resistance. This system establishes a composite strengthening mechanism at high-temperature friction interfaces characterized by structural compatibility, multi-phase load-bearing, and active friction reduction, thereby significantly improving tribological performance under high-temperature service conditions. As the CoCrFeNiMo HEA content increases, the composite coatings exhibit progressively improved high-temperature wear resistance and frictional stability, alongside a reduction in the friction coefficient. The C30 composite coating demonstrates an 86% improvement in wear resistance and a 54% enhancement in frictional stability compared to the NiCr-based counterpart. A composite oxide layer comprising MoO<sub>3</sub>, Cr<sub>2</sub>O<sub>3</sub>, Co<sub>3</sub>O<sub>4</sub>, NiFe<sub>2</sub>O<sub>4</sub>, and Fe<sub>2</sub>O<sub>3</sub> forms on the wear surface of the CoCrFeNiMo HEA-based coatings. Conversely, the corrosion resistance of the coatings decreases with increasing HEA content. The C10 composite coating demonstrates optimal corrosion resistance, attributed to a strengthening mechanism involving the formation of a dense passive film coupled with synergistic two-phase protection, leading to substantially enhanced anti-corrosion performance.</p>

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High-Temperature Tribological Performance and Corrosion Resistance of CoCrFeNiMo-Cr3C2 Composite Coatings

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Longzhi Zhao,
  • Junjie Luo,
  • Daoda Zhang,
  • Mingjuan Zhao,
  • Xiaoyong Li,
  • Lingling Xiong

摘要

The application of NiCr-Cr3C2 coatings in high-temperature tribo-corrosive environments is significantly limited by the incompatible oxidation response and pronounced electrochemical mismatch between the carbides and the NiCr matrix. In this work, NiCr-Cr3C2 and CoCrFeNiMo-Cr3C2 composite coatings were fabricated via supersonic flame spraying. In comparison to NiCr-based composite coatings, the CoCrFeNiMo high-entropy alloy (HEA) based composite coating exhibits a lower coefficient of friction, enhanced frictional stability, and superior corrosion resistance. This system establishes a composite strengthening mechanism at high-temperature friction interfaces characterized by structural compatibility, multi-phase load-bearing, and active friction reduction, thereby significantly improving tribological performance under high-temperature service conditions. As the CoCrFeNiMo HEA content increases, the composite coatings exhibit progressively improved high-temperature wear resistance and frictional stability, alongside a reduction in the friction coefficient. The C30 composite coating demonstrates an 86% improvement in wear resistance and a 54% enhancement in frictional stability compared to the NiCr-based counterpart. A composite oxide layer comprising MoO3, Cr2O3, Co3O4, NiFe2O4, and Fe2O3 forms on the wear surface of the CoCrFeNiMo HEA-based coatings. Conversely, the corrosion resistance of the coatings decreases with increasing HEA content. The C10 composite coating demonstrates optimal corrosion resistance, attributed to a strengthening mechanism involving the formation of a dense passive film coupled with synergistic two-phase protection, leading to substantially enhanced anti-corrosion performance.