Sustainable WC-Fe Based Coatings by High-Velocity Air Fuel Spraying: A Potential Alternative to WC-Co Based Coatings

Abstract The objective of this work was to explore iron-based green binders as a potential alternative to cobalt-based binders. WC-FeCrNiMo powders with varying particle sizes (fine 25/5 μm and coarse 45/15 μm) were deposited using HVAF spraying with different nozzle configurations. The standard WC-CoCr powder was deposited for comparison. The microstructure and hardness of the deposited coatings were thoroughly analyzed. Performance evaluation included ball-on-disk sliding wear tests, air jet erosion tests, and corrosion tests.