Wear behavior of HVOF-sprayed Fe-based amorphous coatings

The wear behavior of Fe48Cr15Mo14C15B6Y2 amorphous coatings prepared by high velocity oxygen fuel (HVOF) thermal spraying was studied under dry sliding conditions in a ball-on-plate mode using alumina ball as the counterpart. It was found that the friction coefficient and the wear rate of the coating are around 0.3–0.4, and (3–19) × 10−5 mm3 N−1 m−1, respectively. Compared with traditional steels and other wear-resistant coatings, such as hard Cr and Al2O3 coatings, the Fe-based amorphous coating shows higher wear resistance. The wear rate is independent of the applied load, but increases linearly with the increase of sliding speed. The dominating wear mechanism of the Fe-based amorphous coating is by oxidative wear coupled with delamination wear, where the oxidation process is governed by inward diffusion of oxygen.

► The high velocity oxygen fuel sprayed Fe-based amorphous coatings show excellent wear resistance.
► It is about 2–3 times better than the AISI 1045 steel substrate and conventional hard Cr coating.
► The wear rate of the amorphous coatings increase linearly with increasing sliding speed.
►  The wear mechanism of the Fe-based amorphous coating is dominated by oxidative wear coupled with delamination wear.
► Oxidation process is governed by inward diffusion of oxygen.