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<p>AISI 304 stainless steel used in turbine components experiences severe sliding wear and cavitation erosion, necessitating high performance protective coatings; WC based cermet coatings applied by high velocity oxy fuel (HVOF) spraying offer strong wear and erosion resistance, and their mechanical performance can be further enhanced through nanoscale reinforcement such as graphene. In this work, WC-17Co and WC-17Co + graphene coatings were deposited on AISI 304 using optimized HVOF parameters and characterized for microstructure, elemental distribution, and phase stability, followed by sliding wear testing at and cavitation erosion evaluation under a three-factor full factorial design varying jet velocity (20–40&#xa0;m/s), impingement angle (30–90°), and stand-off distance (4–12&#xa0;cm). The WC-17Co coating achieved a good wear-rate reduction relative to uncoated AISI 304, while graphene reinforcement provided an additional wear rate reduction relative to WC-17Co; furthermore, graphene improved splat cohesion, restricted inter-splat delamination, and enhanced energy dissipation during elevated temperature sliding. Cavitation tests showed that WC-17Co + graphene offered the highest erosion resistance enhancement due to improved crack-bridging and moderated brittle fracture behaviour. Overall, the incorporation of graphene into WC-17Co coatings significantly improved wear and cavitation performance, demonstrating their suitability as durable surface engineering solutions for AISI 304 components operating under aggressive conditions.</p>

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Enhanced Sliding Wear and Cavitation Erosion Resistance of WC-17Co Graphene Composite Coatings on AISI 304 Stainless Steel Deposited by HVOF

  • 期刊论文

  • 发表日期：

    2025年12月21日

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  • Harvinder Singh,
  • Nitin Kumar,
  • Vivek John,
  • Ajay Kumar,
  • Kaushal Kumar,
  • Jeewan Singh,
  • Abhijit Bhowmik

摘要

AISI 304 stainless steel used in turbine components experiences severe sliding wear and cavitation erosion, necessitating high performance protective coatings; WC based cermet coatings applied by high velocity oxy fuel (HVOF) spraying offer strong wear and erosion resistance, and their mechanical performance can be further enhanced through nanoscale reinforcement such as graphene. In this work, WC-17Co and WC-17Co + graphene coatings were deposited on AISI 304 using optimized HVOF parameters and characterized for microstructure, elemental distribution, and phase stability, followed by sliding wear testing at and cavitation erosion evaluation under a three-factor full factorial design varying jet velocity (20–40 m/s), impingement angle (30–90°), and stand-off distance (4–12 cm). The WC-17Co coating achieved a good wear-rate reduction relative to uncoated AISI 304, while graphene reinforcement provided an additional wear rate reduction relative to WC-17Co; furthermore, graphene improved splat cohesion, restricted inter-splat delamination, and enhanced energy dissipation during elevated temperature sliding. Cavitation tests showed that WC-17Co + graphene offered the highest erosion resistance enhancement due to improved crack-bridging and moderated brittle fracture behaviour. Overall, the incorporation of graphene into WC-17Co coatings significantly improved wear and cavitation performance, demonstrating their suitability as durable surface engineering solutions for AISI 304 components operating under aggressive conditions.