Parametric optimization corrosion erosive wear and XPS response of FeCrCoAlTiB and FeCrCoNiSiB coatings on Q235 steel substrate by HVOF spraying using taguchi method

Abstract In the study high-velocity oxy-fuel thermal spraying to create Fe32Cr21Co21Al16Ti5B5 and Fe43Cr16Co12Al14Ti5B10, Fe32Cr21Co21Ni16Si5B5 and Fe43Cr16Co12Ni14Si5B10 coatings on Q235 steel substrates. Jet-type testing is used to examine the coatings’ resistance to slurry wear. Researchers examined the surface to learn more about the erosion process. Taguchi analysis and a wear model confirm the significance of the selected important factors. The wear model’s proposed mechanism shows remarkable agreement with the data. Coating loss may be attributed to several causes, including mixed ploughing, and cutting, platelet development, abrasion grooves, and cracking. The outcomes showed that the effect speed was the main contributing variable, the contribution ratio reached 65% to 70%, for the impact velocity of coating no 1 to 4. In contrast, it is recognized that impact velocity > impingement angle > erodent feed rate > erodent size is the most important sequence. Micro-cutting, mixed cutting, and ploughing were the essential disintegration systems for all coatings at low impingement points. In contrast, platelets were detected under normal impingement angles, as confirmed by SEM analysis. Both coatings seem to form passivation films, as shown by their greater Ecorr values relative to the substrate. Fe, Co, Cr, Al, and O all show up as peaks in XPS analyses.