Microstructural Charactistics of Plasma Sprayed NiCrBSi Coatings and Their Wear and Corrosion Behaviors

Abstract

Nickel-based alloys are commonly used as protective coating materials for surface protection applications owing to their superior resistance to corrosion, wear and high-temperature oxidation. It is urgent to study the fundamental mechanism between the structure and corrosion properties of the Nickel-base composite coatings. This paper, therefore, focuses on clarifying the mechanisms of the microstructure influencing the acid corrosion and mechanical characteristics of the as-sprayed NiCrBSi coating and post-heat-treated coating. The formation mechanisms of the amorphous phase of flat particles during the plasma spray process were studied by using X-ray diffraction analysis, Raman spectroscopy and confocal laser scanning microscope at first. Then the evolutionary process of the corrosion structure and phase of the coating in the accelerated corrosion experiment is directly visualized by using scanning electron microscopy and energy spectrum analysis. The mechanical properties of the amorphous NiCrBSi coatings are lastly measured by microhardness and friction wear tests. The critical phenomena and results help to elucidate the relative influence of the surface features of atmospheric plasma sprayed coatings on acid corrosion responses and wear resistance, aiming at contributing to the development of a protective technique for electrical engineering.

Different Primary Gas Flow Rates in Determining the Flattening Behavior of In-Flight Particles in Plasma-Sprayed NiCrBSi Coatings and the Resultant Microstructure and Hardness

“…However, notable disparities emerge in the intensities of individual peaks. Additionally, the broadening of γ-Ni peaks signifies the presence of the amorphous phase within the coating [14,29]. According to the extensive range covered by each diffraction peak, it is possible to use an approximative technique for estimating the volume fraction of the amorphous phase within the XRD pattern.…”

“…Among several Ni-based alloys, NiCrBSi alloy stands out as self-fluxing and is widely used in engines, piston rods, and boilers due to its high wear and corrosion resistance [12,13]. Furthermore, the good amorphous formability of NiCrBSi alloy provides high mechanical strength and resistance to wear and corrosion [14]. Typically, NiCrBSi coatings are prepared using thermal spraying, such as atmospheric plasma spraying (APS) [11,15], flame spraying (FS) [16,17], or high-speed oxygen fuel spraying (HVOF) [18,19].…”

Characterization and wear properties of plasma sprayed Cr3C2 and Stellite coatings on Inconel 625

“…Dinesh Babu et al [17] have explored tribological characteristics of plasma sprayed TiO 2 coating on Al/ SiC composites and stated that least Coefficient and wear resistance were attained for the surface coated samples. Songqiang Huang et al [18] studied the wear properties of plasma sprayed Nickel Chrome Boron Silicium (NiCrBSi) coatings on stainless steel and reported that wear and friction behavior have been improved for coated samples. Cornelia Cirlan Paleu et al [19] examined the tribological characteristics of AMDRY 1371 (Mo-NiCrFeBSiC) in an atmospheric plasma spray coated parallelepipedal steel and concluded that wear resistance has been increased based on the process parameters.…”

Chemical Composition Effects on the Microstructure and Hot Hardness of NiCrSiFeB Self-Fluxing Alloys Manufactured via Gravity Casting

“…The common coating techniques used for these alloys are flame spraying [3][4][5][6], plasma spraying [7][8][9], high-velocity oxygen fuel spraying (HVOF) [10][11][12], laser cladding [13][14][15][16][17], laser metal deposition (LMD) [18,19], non-vacuum electron beam cladding [20,21], laser powder bed fusion (LPBF) [22], and the plasma transferred arc welding (PTAW) processes [23]. All of these techniques have high solidification rates that can lead to different types of defects, and they can also enhance the porosity and cracking susceptibility of these materials [24].…”