Cobalt free metallic binders for HVOF thermal sprayed wear resistant coatings

Thermal sprayed HVOF WC-based cermet coatings containing various metallic binders have been used in several different applications in industries that require abrasive sliding wear resistance, such as hydraulic pistons, shafts or bearings. The potential dangerousness and cost increase off cobalt-based metallic binders, underlining the challenge in reducing reliance on this metal as metallic binder in wear resistant coatings. The present work aims to study the feasibility of WC-NiMoCrFeCo, WC-CrC-Ni and WC-FeCrAl coatings, in contrast to conventional WC-CoCr, by evaluating their microstructure, mechanical, tribological and corrosion resistance properties. Commercially feedstock powders were sprayed onto steel plates using a kerosene-fuelled HVOF WokaJet 400 gun. The WC-CoCr coating shows a slightly highest hardness than WC-NiMoCrFeCo and WC-FeCrAl coatings, showing a slight trend towards an increase in the wear rate as the coating hardness decreases. The WC-CrC-Ni coating is significantly the softest and least wear resistant coating, as a consequence of the presence of a high percentage of lower hardness CrC particles. Nevertheless, this coating shows similar corrosion resistance to of conventional WC-CoCr coating, while the WC-NiMoCrFeCo and WC-FeCrAl coatings show a slightly worse corrosion resistance.