<p>This study investigates the high-temperature tribological performance of nano-CeO<sub>2</sub>-modified multimodal Cr<sub>3</sub>C<sub>2</sub>-NiCr coatings (NMC) fabricated via high-velocity oxygen fuel (HVOF) spraying, in comparison with conventional Cr<sub>3</sub>C<sub>2</sub>-NiCr coatings (CC). Through comprehensive microstructural characterization, mechanical property evaluation, and high-temperature friction-wear tests (500-700&#xa0;°C, 20-50N), the synergistic effects of multimodal architecture and CeO<sub>2</sub> modification were elucidated. Results demonstrate that NMC exhibits a refined multimodal architecture comprising uniformly distributed nano-, submicron-, and micron-scale Cr<sub>3</sub>C<sub>2</sub> particles embedded in a NiCr matrix, achieving significantly reduced porosity (0.30 ± 0.12% vs. 1.41 ± 0.15% for CC) and enhanced microhardness (1014.9 ± 72.2 HV<sub>0</sub>.<sub>3</sub> vs. 906.4 ± 47.8 HV<sub>0</sub>.<sub>3</sub>). These improvements are attributed to synergistic mechanisms involving nano-CeO<sub>2</sub>-induced solid-solution strengthening, grain refinement, and hierarchical carbide dispersion, which collectively optimize interfacial bonding, minimize structural defects, and enhance load-bearing capacity. At elevated temperatures, NMC achieves a lower friction coefficient (0.49-0.72 vs. 0.55-1.25 for CC) and reduced wear rates (1.88-3.3 × 10<sup>−5</sup> mm<sup>3</sup>/N·m vs. 4.03-5.74 × 10<sup>−5</sup> mm<sup>3</sup>/N·m for CC), owing to the formation of adherent Cr<sub>2</sub>O<sub>3</sub>-rich tribofilms and suppressed decarburization via CeO<sub>2</sub>-mediated interfacial passivation. Wear surface and debris observations indicate that CC is dominated by adhesive wear, severe third-body abrasion, and lamellar delamination, whereas NMC shows mainly adhesive/abrasive wear with more persistent Cr<sub>2</sub>O<sub>3</sub>-rich tribofilms. The synergistic effect of the multimodal architecture and nano-CeO<sub>2</sub> modification improves NMC’s high-temperature tribological performance. These findings highlight the potential of nano-modified multimodal Cr<sub>3</sub>C<sub>2</sub>-NiCr coatings for high-temperature tribological applications, particularly in demanding industrial environments such as continuous casting crystallizers.</p>

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High-Temperature Tribological Performance of Nano-Modified Multimodal Cr3C2-NiCr Coatings

  • Chenxi Shi,
  • Ming Hu,
  • Huan Wang,
  • Shibin Liu,
  • Qinglin Gong

摘要

This study investigates the high-temperature tribological performance of nano-CeO2-modified multimodal Cr3C2-NiCr coatings (NMC) fabricated via high-velocity oxygen fuel (HVOF) spraying, in comparison with conventional Cr3C2-NiCr coatings (CC). Through comprehensive microstructural characterization, mechanical property evaluation, and high-temperature friction-wear tests (500-700 °C, 20-50N), the synergistic effects of multimodal architecture and CeO2 modification were elucidated. Results demonstrate that NMC exhibits a refined multimodal architecture comprising uniformly distributed nano-, submicron-, and micron-scale Cr3C2 particles embedded in a NiCr matrix, achieving significantly reduced porosity (0.30 ± 0.12% vs. 1.41 ± 0.15% for CC) and enhanced microhardness (1014.9 ± 72.2 HV0.3 vs. 906.4 ± 47.8 HV0.3). These improvements are attributed to synergistic mechanisms involving nano-CeO2-induced solid-solution strengthening, grain refinement, and hierarchical carbide dispersion, which collectively optimize interfacial bonding, minimize structural defects, and enhance load-bearing capacity. At elevated temperatures, NMC achieves a lower friction coefficient (0.49-0.72 vs. 0.55-1.25 for CC) and reduced wear rates (1.88-3.3 × 10−5 mm3/N·m vs. 4.03-5.74 × 10−5 mm3/N·m for CC), owing to the formation of adherent Cr2O3-rich tribofilms and suppressed decarburization via CeO2-mediated interfacial passivation. Wear surface and debris observations indicate that CC is dominated by adhesive wear, severe third-body abrasion, and lamellar delamination, whereas NMC shows mainly adhesive/abrasive wear with more persistent Cr2O3-rich tribofilms. The synergistic effect of the multimodal architecture and nano-CeO2 modification improves NMC’s high-temperature tribological performance. These findings highlight the potential of nano-modified multimodal Cr3C2-NiCr coatings for high-temperature tribological applications, particularly in demanding industrial environments such as continuous casting crystallizers.