Parametric study of abrasive wear of Co–CrC based flame sprayed coatings by Response Surface Methodology

• The hardness increases with the increases in chromium carbide concentration.
• The load and sliding distance have more severe effect on abrasive wear of coating.
• Abrasive wear rate of 20 wt% chromium carbide coating is lower as compared to 0 wt%.

Co base powder (EWAC1006 EE) was modified with the addition of 20%WC and the same was further modified by varying amounts of chromium carbide (0, 10 and 20 wt%) in order to develop three different coatings. Microstructure, elemental mapping XRD, porosity and hardness analysis of the three coatings was carried out. The effect of CrC concentration (C), load (L), abrasive size (A), sliding distance (S) and temperature (T) on abrasive wear of these flame sprayed coatings was investigated by Response Surface Methodology and an abrasive wear model was developed. A comparison of modeled and experimental results showed 5–9% error.