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HVOF- and HVAF-Sprayed Cr3C2-NiCr Coatings Deposited from Feedstock Powders of Spherical Morphology: Microstructure Formation and High-Stress Abrasive Wear Resistance Up to 800 °C

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Abstract

Chromium carbide-based coatings are commonly applied to protect surfaces against wear at high temperatures. This work discusses the influence of feedstock powder and spray torch selection on the microstructure and high-stress abrasion resistance of thermally sprayed Cr3C2-NiCr coatings. Four commercial feedstock powders with spherical morphology and different microstructures were deposited by different high-velocity spray processes, namely third-generation gas- and liquid-fueled HVOF torches and by the latest generation HVAF torch. The microstructures of the coatings were studied in the as-sprayed state and after various heat treatments. The high-stress abrasion resistance of as-sprayed and heat-treated coatings was tested at room temperature and at 800 °C. The study reveals that the selection of the spray torch mainly affects the room temperature abrasion resistance of the as-sprayed coatings, which is due to differences in the embrittlement of the binder phase generated by carbide dissolution. At elevated temperatures, precipitation and growth of secondary carbides yields a fast equalization of the various coatings microstructures and wear properties.

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Notes

  1. A typical flame temperature of 1900-1950 °C is specified by the manufacturer Uniquecoat Technologies.

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Acknowledgments

This work was co-funded by the Austrian Research Promotion Agency (FFG) under Project Nos. 839126 and 849109 (COMET K2 XTribology), and the German Ministry of Economic Affairs and Energy via AiF under Project Nos. IGF 91 EBR, DVS no. 02.091. We thank Durum Verschleißschutz GmbH (Willich, Germany), GTV Verschleißschutz GmbH (Luckenbach, Germany), H.C. Starck GmbH (München, Germany) and Oerlikon Metco Woka GmbH (Barchfeld, Germany) for providing the feedstock powders, voestalpine AG (Linz, Austria) for providing the substrates, and KVT Kurlbaum AG (Osterholz-Scharmbeck, Germany) and Putzier Oberflächentechnik GmbH (Leichlingen, Germany) for the deposition of the coatings, as well as GfE Fremat GmbH (Freiberg, Germany) for the non-metal analyses.

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Authors and Affiliations

  1. AC2T Research GmbH, Viktor Kaplan-Str. 2 C, 2700, Wiener Neustadt, Austria

    L. Janka & J. Norpoth

  2. Department of Materials Science, Tampere University of Technology, Korkeakoulunkatu 6, 33101, Tampere, Finland

    L. Janka

  3. Fraunhofer IWS, Fraunhofer Institute for Materials and Beam Technology, Winterbergstr. 28, 01277, Dresden, Germany

    R. Trache

  4. Fraunhofer IKTS, Fraunhofer Institute for Ceramic Technologies and Systems, Winterbergstr. 28, 01277, Dresden, Germany

    S. Thiele & L.-M. Berger

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  1. L. Janka
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Correspondence to J. Norpoth.

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Janka, L., Norpoth, J., Trache, R. et al. HVOF- and HVAF-Sprayed Cr3C2-NiCr Coatings Deposited from Feedstock Powders of Spherical Morphology: Microstructure Formation and High-Stress Abrasive Wear Resistance Up to 800 °C. J Therm Spray Tech 26, 1720–1731 (2017). https://doi.org/10.1007/s11666-017-0621-y

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