Three-Body Abrasive Wear Behavior of WC-10Cr3C2-12Ni Coating for Ball Mill Liner Application

Abstract

Carbide coatings are frequently used to improve the wear resistance of industrial components in various wear environments. In this research, aiming at the service characteristics of easy wear and short service life of ball mill liners, WC–10Cr3C2–12Ni coatings were prepared by supersonic flame spraying technology (HVOF). The reciprocating sliding tests were conducted under four different WC particle size conditions, and the differences in the tribological behavior of the coatings and three–body abrasive wear mechanism were obtained. The findings reveal that the average nanohardness of the WC–Cr3C2–Ni coating is nearly five times greater than that of the steel substance. The COF of tribo-pairs decreases and then increases as the particle size increases. In the case of no particles, the surface of the coating is slightly worn, with fatigue and oxidative wear being the primary wear mechanisms. Small particles (1.5 μm and 4 μm) are crushed and coated on the coating surface, in which the extremely fine particles are plasticized to form friction layers that have a protective effect on the coatings. The protective effect of the particles disappears as the particle size increases and is replaced by a powerful chiseling effect on the coatings, resulting in serious material loss. The particle size has a direct relationship with coating wear.

Effect of Cobalt and Chromium Content on Microstructure and Properties of WC-Co-Cr Coatings Prepared by High-Velocity Oxy-Fuel Spraying

“…The reason is as follows: because Cr has higher hardness and poorer wettability with WC in comparison to Co [18], it will undoubtedly increase the brittleness of the metal-binding phase and decrease the bonding force between the metal-binding phase and WC; therefore, the cracks in the coating are more accessible to propagate under the action of the indenter during the testing of fracture toughness. In addition, the fracture toughness obtained in this work is comparable to those of the WC-10Co-4Cr coatings reported in the other literature [4,7], but it is lower than that of the WC-Co coating for the same reasons as above [10].…”

“…All the WC-Co-Cr powders were sprayed on a rinsed and sandblasted low-carbon steel substrate (16Mn steel, its nominal mass percentage content, C: 0.13-0.19, Si: 0.20-0.60, Mn: 1.20-1.60, Cr ≤ 0.30, P ≤ 0.030, S ≤ 0.030, Ni ≤ 0.30, Cu ≤ 0.25, Anshan Iron and Steel Group Co., LTD., Anshan, Liaoning, China) using Praxair-JP-8000 HVOF equipment (Praxair Surface Technologies, INC, Indianapolis, IN, USA) with balanced and identical spray parameters (Table 2) [10]. The barrel was perpendicular to the surface of the substrate; the spray gun was traversed along the horizontal direction according to the Z-shaped trajectory.…”

Tribocorrosive Aspects of Tungsten Carbide, Silicon Nitride, and Martensitic Steel under Fretting-like Conditions

“…These particles acted as a wear-promoting third-body in the tribosystem and were seen to be responsible for the extremely high friction. Two recent research articles discuss the influence of third-body hard-phase particle size and agree that friction losses can dramatically increase at certain particle dimensions, which is related to a chiseling effect of the debris [85,86]. The microscopic image of the HT1/1.4108 contact showed an expressed center in the HT1 wear scar (Figure 7a), where grooves from sliding wear appeared sharp-edged and less regular, thus attenuating light reflection under macroscopic view.…”

Influence of Pre-Milling of Cr3C2-25 NiCr Spray Powder on the Fatigue Life of HVOF-Sprayed Coating on ASTM A516 Steel Substrate

“…High velocity oxygen fuel (HVOF) thermal spraying is a technique based on the hypersonic flame at speeds up to 3000 m/s that releases high energy, which is converted into heat and pressure [ 3 , 17 , 18 , 19 , 20 , 21 ]. Particles reach the substrate and form a dense and hard coating, with low porosity and high adhesion strength of the coating to the substrate after the HVOF deposition [ 8 , 22 , 23 , 24 ]. The HVOF hamper phase transformations due to the faster powder speed, heating and cooling, and the lower heat transfer to the feedstock.…”