Fatigue behavior of a structural steel coated with a WC–10Co–4Cr/Colmonoy 88 deposit by HVOF thermal spraying

The fatigue behavior of a SAE 4340 steel, coated with a 50% WC–10Co–4Cr/50% Colmonoy 88 deposit, by high velocity oxygen fuel (HVOF) thermal spray, has been investigated. The change in the maximum alternating stress with the number of cycles to fracture has been described by means of the relationship advanced by Stromeyer. A fractographic analysis has been carried out on some representative fracture surfaces, by means of scanning electron microscopy (SEM) techniques. The mechanical properties of the coating were characterized by means of nanoindentation tests. The results indicate that the coating is highly heterogeneous. Its deposition gives rise to a decrease in the fatigue strength of the substrate of ∼30%, in comparison with the uncoated substrate. The decrease in fatigue strength is due to the presence of stress concentrators at the substrate–coating interface, as well as the intrinsic characteristics of the coating. ► We investigated the fatigue behavior of a 4340 steel coated with a WC–10Co–4Cr/Colmonoy 88 deposit. ► The coating was deposited by HVOF thermal spray after prior grit blasting and it is very heterogeneous. ► The mechanical properties of the coating were characterized by means of nanoindentation tests. ► The coating deposited gives rise to a significant decrease in the fatigue strength of the substrate. ► The decrease in fatigue strength is due to the presence of stress concentrators at the substrate–coating interface.