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<p>Stainless steel 316 (SS316) is favored in marine and aerospace industries for its resistance to corrosion and mechanical reliability. The limited wear resistance of the material poses challenges for its application at elevated operating temperatures. To effectively address this limitation, Ni-Cr-Fe and Ni-Cr-Al coatings were expertly applied to SS316 substrates using the high-velocity oxygen fuel (HVOF) process. The examination of the coatings tribological behavior utilizing an alumina ball-on-disk configuration over a temperature range from room temperature to 800&#xa0;°C, under applied loads of 10 N and 20 N. A comprehensive suite of characterization techniques includes SEM, XRD, microhardness testing, density measurements, porosity analysis, bond strength evaluation, and surface roughness assessments. Wear mechanisms were further investigated through 3D profilometry and SEM–EDS. Both coating systems showed cohesive failure at 25 N, while higher loads (70-100&#xa0;N) promoted a mixed cohesive–adhesive failure mode. Ni-Cr-Fe exhibited higher hardness and bond strength than Ni-Cr-Al. The bare SS316 substrate demonstrated a continuous rise in wear rate with increasing temperature. In contrast, both coatings displayed peak wear and friction values at 300&#xa0;°C, followed by a reduction at 600-800&#xa0;°C due to the development of protective oxide scales (Fe<sub>2</sub>O<sub>3</sub>, NiO, and NiCr<sub>2</sub>O<sub>4</sub>). Abrasive and fatigue wear mechanisms dominated at room temperature, while oxidative and adhesive wear became prominent at 800&#xa0;°C. Overall, Ni-Cr-Fe outperformed Ni-Cr-Al and the uncoated substrate regarding wear resistance and frictional stability.</p>

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Tribological Analysis of Ni-Cr-Fe and Ni-Cr-Al Coatings on SS316 Under Elevated Temperatures

  • 期刊论文

  • 发表日期：

    2026年6月16日

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  • A. N. V. Siva Prasad,
  • Netrananda Behera,
  • Sriharsha Kumar,
  • T. V. Chandramouli,
  • Ranjan Yadav,
  • Swaraj Suman Soans,
  • M. R. Ramesh,
  • Sharnappa Joladarashi

摘要

Stainless steel 316 (SS316) is favored in marine and aerospace industries for its resistance to corrosion and mechanical reliability. The limited wear resistance of the material poses challenges for its application at elevated operating temperatures. To effectively address this limitation, Ni-Cr-Fe and Ni-Cr-Al coatings were expertly applied to SS316 substrates using the high-velocity oxygen fuel (HVOF) process. The examination of the coatings tribological behavior utilizing an alumina ball-on-disk configuration over a temperature range from room temperature to 800 °C, under applied loads of 10 N and 20 N. A comprehensive suite of characterization techniques includes SEM, XRD, microhardness testing, density measurements, porosity analysis, bond strength evaluation, and surface roughness assessments. Wear mechanisms were further investigated through 3D profilometry and SEM–EDS. Both coating systems showed cohesive failure at 25 N, while higher loads (70-100 N) promoted a mixed cohesive–adhesive failure mode. Ni-Cr-Fe exhibited higher hardness and bond strength than Ni-Cr-Al. The bare SS316 substrate demonstrated a continuous rise in wear rate with increasing temperature. In contrast, both coatings displayed peak wear and friction values at 300 °C, followed by a reduction at 600-800 °C due to the development of protective oxide scales (Fe2O3, NiO, and NiCr2O4). Abrasive and fatigue wear mechanisms dominated at room temperature, while oxidative and adhesive wear became prominent at 800 °C. Overall, Ni-Cr-Fe outperformed Ni-Cr-Al and the uncoated substrate regarding wear resistance and frictional stability.