Microstructure and high-temperature tribological behaviours of nano-HfC reinforced Inconel 625 composite coating by plasma-transferred arc welding

The study involved plasma arc transfer welding (PTAW) for preparing coatings of Inconel 625 alloys that contained different amounts of nano-sized hafnium carbide (nano-HfC) particles. The impact of nano-HfC on the microstructure evolution and mechanical properties of PTAWed Inconel 625 were investigated. The research reveals that nano-HfC decomposes during the high-temperature plasma arc process and then react with O element to generate nano-HfO2. These HfO2 can serve as nucleation sites for MC carbides, which restricts the growth of secondary dendrite arms, leading to a more disordered grain growth direction. Simultaneously, the decomposition of HfC can increase the C/Nb ratio of the matrix, effectively suppressing Laves phase formation while encouraging the development of MC carbides. Compared with IN625, the wear rate of composites at room temperature and 600 °C were decreased. Notably, at 600 °C, the wear rate of the coating with 0.5 wt% HfC is the lowest among all the samples, as reflected by a noteworthy reduction in wear rate of 50 %. This is mainly attributed to the refinement of γ matrix, reduction of Laves phase as well as precipitation of the fine-sized MC carbides. This work illustrates that adding nano-HfC is an effective way to improve the wear resistance of the PTAWed Inconel 625. •Nano-HfC exists in the form of nano-HfO2, serving as nucleation sites for carbides.•The addition of nano-HfC suppresses the formation of Laves phases and promotes the precipitation of carbides.•The wear resistance of the coating is enhanced by the addition of nano-HfC particles.