Design and Fabrication of Wear-Resistant Coatings Using Thermal Spray Techniques

This study focuses on the design and fabrication of wear-resistant coatings using advanced thermal spray techniques to enhance the surface durability of engineering components. Various coating materials, including ceramics, metallic alloys, and composite powders, were deposited onto substrate surfaces through controlled thermal spraying processes such as plasma spraying and high-velocity oxy-fuel (HVOF) spraying. The microstructural characteristics, adhesion strength, and wear resistance of the fabricated coatings were systematically evaluated under different operational conditions. Experimental results demonstrate that optimized thermal spray parameters significantly improve coating density, hardness, and resistance to abrasive and erosive wear, highlighting the potential of these coatings for extending the service life of critical industrial components. The results demonstrate that coating performance strongly depends on deposition technique and process parameters, with HVOF-sprayed composite coatings exhibiting superior density, adhesion, and wear resistance. This study presents a comparative parametric analysis of thermal spray techniques rather than a universal coating framework.

ear-resistant coatings, Thermal spray techniques, Plasma spraying, HVOF spraying, Surface engineering, Abrasive wear, Coating microstructure, Material durability

1. S. Dinavahi, V. K. Champagne, and D. J. Helfritch, “Comparison of Empirical and Theoretical Computations of Velocity for a Cold Spray Nozzle,” 2009 DoD High Performance Computing Modernization Program Users Group Conference, pp. 27–31, 2009. [Google Scholar] [Crossref]

2. X-ray diffraction, Available at: https://www.merriam-webster.com/dictionary/X-ray%20diffraction [Online], Accessed on: December 26th, 2019. [Google Scholar] [Crossref]

3. V. K. Sharma and V. Kumar, “Development of rare-earth oxide-based hybrid AMCs reinforced with SiC/Al2O3: Mechanical & metallurgical characterization,” J. Mater. Res. Technol., vol. 8, no. 2, pp. 1971–1981, 2019. [Google Scholar] [Crossref]

4. B. Fotovvati, N. Namdari, and A. Dehghanghadikolaei, “On Coating Techniques for Surface Protection: A Review,” J. Manuf. Mater. Process., vol. 3, no. 1, p. 28, 2019. [Google Scholar] [Crossref]

5. Gobind, J. Parshad, and N. K. Grover, “Improving Wear Resistance of Grey Cast Iron using Detonation Gun Sprayed Coatings: A Review,” Int. J. Eng. Manag. Res., vol. 5, no. 1, pp. 303–307, 2015. [Google Scholar] [Crossref]

6. D. Mudgal, S. Kumar, S. Singh, and S. Prakash, “Corrosion Behavior of Bare, Cr3C2-25%(NiCr), and Cr3C2-25%(NiCr)+0.4%CeO2-Coated Superni 600 Under Molten Salt at 900 °C,” J. Mater. Eng. Perform., vol. 23, no. 11, pp. 3805–3818, 2014. [Google Scholar] [Crossref]

7. A. Scrivani et al., “A Contribution to the Production and Characterization of HVOF Coatings for Application in the Petrochemical Field,” Proc. Int. Therm. Spray Conf., vol. 250, pp. 141–148, 2001. [Google Scholar] [Crossref]

8. A. Lekatou, E. Regoutas, and A. E. Karantzalis, “Corrosion behavior of cermet-based coatings with a bond coat in 0.5 M H2SO4,” Corros. Sci., vol. 50, no. 12, pp. 3389–3400, 2008. [Google Scholar] [Crossref]

9. Z. Zhou, L. Wang, F. C. Wang, H. F. Zhang, Y. B. Liu, and S. H. Xu, “Formation and corrosion behavior of Fe-based amorphous metallic coatings by HVOF thermal spraying,” Surf. Coatings Technol., vol. 204, no. 5, pp. 563–570, 2009. [Google Scholar] [Crossref]

10. K. N. Balan, B. R. R. Bapu, A. J. Rajan, and Manimaran, “Enhancement of surface property by thermal spray coating technique – A Review,” Proceedings of 10th IRAJ International Conference, pp. 29–31, 2013. [Google Scholar] [Crossref]

11. S. S. Chatha, H. S. Sidhu, and B. S. Sidhu, “Characterization and Corrosion-Erosion Behavior of Carbide based Thermal Spray Coatings,” Journal of Minerals & Materials Characterization & Engineering, vol. 11, no. 6, pp. 569–586, 2012. [Google Scholar] [Crossref]

12. R. Bhatia, H. S. Sidhu, and B. S. Sidhu, “High Temperature Behavior of Cr3C2-NiCr Coatings in the Actual Coal-Fired Boiler Environment,” ASM International (ASM) and The Minerals, Metals & Materials Society (TMS), pp. 70–86, 2015. [Google Scholar] [Crossref]

13. N. K. Mishra, N. Kumar, and S. B. Mishra, “Hot Corrosion Behavior of Detonation Gun Sprayed Al2O3 -40TiO2 Coating on Nickel Based Superalloys at 900°C,” Indian J. Mater. Sci., vol. 2014, pp. 1–5, 2014. [Google Scholar] [Crossref]

14. H. Singh, M. S. Grewal, H. S. Sekhon, and R. G. Rao, “Sliding wear performance of high-velocity oxy-fuel spray A12O3/TiO2 and Cr2O3 coatings,” Proc. Inst. Mech. Eng. Part J J. Eng. Tribol., vol. 222, no. 4, pp. 601–610, 2008. [Google Scholar] [Crossref]

15. M. Akhtari Zavareh, A. A. D. M. Sarhan, B. B. Razak, and W. J. Basirun, “The tribological and electrochemical behavior of HVOF-sprayed Cr3C2-NiCr ceramic coating on carbon steel,” Ceram. Int., vol. 41, no. 4, pp. 5387–5396, 2015. [Google Scholar] [Crossref]

16. V. N. Shukla, V. K. Tewari, and R. Jayaganthan, “Comparison of tribological behavior of Cr3C2/NiCr coatings deposited by different thermal spray techniques: A review,” National Conference on Advancements and Futuristic Trends in Mechanical and Materials Engineering, pp. 1–5, 2011. [Google Scholar] [Crossref]

17. S. Kamal, R. Jayaganthan, and S. Prakash, “Mechanical and microstructural characteristics of detonation gun sprayed NiCrAlY + 0.4 wt% CeO2 coatings on superalloys,” Mater. Chem. Phys., vol. 122, no. 1, pp. 262–268, 2010. [Google Scholar] [Crossref]

18. S. Praveen and A. Arjunan, “Parametric optimisation of high-velocity oxy-fuel nickel-chromium-silicon-boron and aluminium-oxide coating to improve erosion wear resistance,” Mater. Res. Express, vol. 6, no. 9, pp. 1–16, 2019. [Google Scholar] [Crossref]

19. S. Amin and H. Panchal, “A Review on Thermal Spray Coating Processes,” Int. J. Curr. Trends Eng. Res., vol. 2, no. 4, pp. 556–563, 2016. [Google Scholar] [Crossref]

20. P. Fauchais and A. Vardelle, “Thermal Sprayed Coatings Used Against Corrosion and Corrosive Wear,” Adv. Plasma Spray Appl., pp. 1–38, 2012. [Google Scholar] [Crossref]

• Predictive Health Monitoring Systems for Electric Vehicle Powertrains Using Edge AI and CAN Bus Data
• Internship Portals: A Systematic Review of Current Platforms and Future Directions
• Towards Better Urban Mobility: A Comprehensive Assessment of Pedestrian Infrastructure in Naval, Biliran Province, Philippines
• An Affordable and Sustainable Efficient Color Sorting System Using Arduino and TCS3200 Sensor
• Financial Stress and Mobility Patterns: Implication for Transportation Policy Among Jeepney Passengers