Properties of WC-FeCrAl coatings manufactured by different high velocity thermal spray processes

Of all the WC-FeCrAl coatings, the gas fuelled-HVOF sprayed one exhibited the best wear resistance both in dry sliding conditions (at room temperature as well as at 400 °C) and in dry particle abrasion testing. It indeed achieves the best compromise between density, hardness and low oxidation, so that it can reduce the extent of the brittle cracking phenomena affecting all WC-FeCrAl samples. Its dry sliding wear rate of ≈ 3 ∗ 10− 8 mm3/(Nm) at room temperature is even slightly lower than that of the WC-CoCr reference. Its performance under high temperature sliding and dry particle abrasion conditions is, however, somewhat poorer than that of the reference.