Elevated-Temperature Wear Study of HVOF spray Cr3C2–NiCr-Coated Die Steels

Abstract

Wear and surface damage of tools (die materials) in the hot metal forming industry is a critical problem observed and is producing an adverse effect on the process economy. The problem occurs when tool and workpiece interact at higher temperatures. However, the research related to the wear and friction of dies is still lacking. In the present investigation, tribological (wear and friction) studies were conducted with an aim to explore the potential of Cr3C2–NiCr surface coating. The high-velocity oxy-fuel (HVOF) spray technique was used to formulate the coatings. The microhardness, surface roughness, bond strength, and porosity of the coated specimens were found and analyzed. Subsequently, elevated-temperature wear and friction study of the uncoated and coated specimens were done in the laboratory. The study was conducted at 25 N and 50 N loads. The coated specimens showed an increase in wear resistance at all test parameters. The lowest value of coefficient of friction (COF) and the specific wear-rate for the coated specimens were observed at 400 °C. Wear mechanisms were studied by the scanning electron microscopy (SEM) technique. The wear mechanisms were observed to be adhesive in nature at room temperatures and the combination of abrasive/oxidative/adhesive in nature at higher temperatures for the Cr3C2–NiCr-coated specimens.