Gürgenç, Turan; Macit, Cevher Kürşat; Sömer, Medeni; Aksakal, Bünyamin; Ayık, Merve; Say, Yakup

High-velocity oxy-fuel (HVOF)-sprayed NiCrBSi coatings containing 0, 10, 30, and 50 wt.% WC-Co were evaluated on AZ91D magnesium alloy to determine how the discrete reinforcement level affects surface topography, phase constitution, Vickers microhardness, dry-sliding friction, mass loss, and wear-track microchemistry. As-sprayed surfaces were characterized by three-dimensional profilometry; coating cross-sections and worn surfaces by optical microscopy and SEM/EDS; phase constitution by XRD; and mechanical response by HV0.1 indentation. Dry-sliding tests were performed at 10, 30, and 50 N over 100–1000 m. Increasing WC-Co content raised Sa from 8.8 ± 0.3 to 13.0 ± 0.5 µm and Vickers microhardness from 776 ± 4 to 959 ± 5 HV0.1. XRD indicated a γ-Ni-based matrix containing boride/carbide constituents, while WC, W2C, and Co became increasingly prominent in the reinforced coatings. Boride assignments are based on diffraction evidence, whereas B and C EDS signals were treated semi-quantitatively. The 50 wt.% WC-Co coating exhibited the lowest mass loss and mean coefficient of friction at every load. Its mean friction coefficients were 0.31, 0.35, and 0.41 at 10, 30, and 50 N, corresponding to reductions of 40.1%, 38.9%, and 36.2% relative to AZ91D. At 1000 m, its mass-normalized wear rate indices were 9.0 × 10−4, 4.0 × 10−4, and 5.3 × 10−4 mg N−1 m−1, respectively. Post-wear mapping showed the largest field-scale W-Co-rich fraction in the 50 wt.% coating; however, isolated spectra containing more than 94 wt.% Mg are compatible with local coating penetration/substrate exposure and/or Mg-rich debris. The 50 wt.% composition therefore provided the best combined response among the four tested levels, while intermediate compositions are required to identify a continuous-composition optimum.

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Macit, Cevher Kursat; Aksakal, Bünyamin; Ayık, Merve; Gürgenç, Turan; Aslan, Naim

High-velocity oxy-fuel (HVOF) spraying was used to deposit WC-Co and WC-Co-Cr coatings on high-speed steel in order to determine how binder chemistry and coating thickness jointly control load support, friction, and dry sliding wear resistance. Nominal 50 and 100 µm coatings were compared within the same substrate framework by XRD, FT-IR, SEM/EDX, cross-sectional image analysis, Vickers hardness testing, dry sliding wear testing, and post-wear SEM/EDX. The coatings retained WC as the dominant crystalline phase, while weak overlapping features were associated with binder-rich regions and limited decarburization products. Cross-sectional observations confirmed continuous coating build-up close to the nominal thicknesses and low apparent dark-feature/porosity fractions. All WC-based coatings increased the effective hardness and reduced mass loss relative to uncoated HSS. Among the tested conditions, WC-Co-Cr-100 provided the highest effective hardness and the lowest mass loss after 1000 m sliding, whereas WC-Co-100 produced the lowest mean coefficient of friction. The results show that low friction and high wear resistance are not governed by identical mechanisms: WC-Co favours interfacial shear reduction, while the thicker Cr-containing coating provides superior resistance to material removal through improved carbide retention, binder stability, and coating-scale load support.

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