Comparison of Tribological Behavior of Hard Faced Fe-Based Metallic Composite Coatings Sprayed Using HVOF

Fe-based alloys have recently become well-known for their ability to resist wear and corrosion. Iron, the primary component of alloys, is a cheaper option than alloys made from Co and Ni. There is a need for affordable and easily obtainable coatings based on iron. Coatings in the Fe–Ni–Cr system have demonstrated superior wear resistance compared to other commonly used Fe-based metallic coatings. The Fe-12Ni17Cr2.5Mo2.3Si0.03C based (Metco 41C) metallic coatings were applied onto boiler steel substrates using the High Velocity Oxy-Fuel (HVOF) spraying method. The coatings were examined using X-ray diffraction (XRD), a scanning electron microscope (SEM), and a microhardness tester to determine their density, porosity, microstructure, hardness, and surface roughness. The sliding wear behavior of the substrate and coatings was studied using the pin-on-disk tribometer. Figuring out the wear loss and coefficient of friction. Comparison was made of wear results between the substrate, coatings, and composite coatings. By combining these carbide powders with 30% SiC and WC-12Co particles, the coating’s wear resistance is enhanced in comparison to the Metco 41C coating. In comparison to boiler steel, the Metco 41C + SiC and Metco 41C + WC–Co coatings exhibited a roughly 70% and 40% reduction in volume loss compared with boiler steel respectively.