High temperature erosion behavior of plasma sprayed NiCrAlY/WC-Co/cenosphere coating

High temperature erosive behavior of plasma sprayed NiCrAlY-25WC-Co/cenosphere coating deposited on MDN 321 steel is investigated in the present work. Coating is characterized using Scanning Electron Microscopy (SEM) and X-Ray Diffraction (XRD). Microhardness, porosity, adhesion strength, fracture toughness and ductility of the coating are quantified. Solid particle erosion test is conducted at 200, 400 and 600°C with 30 and 90° impact angles using alumina erodent. Optical profilometer is used to evaluate erosion volume loss. Erosion resistance of the coating is observed to be higher than the substrate for the test temperatures chosen and noted to be more prominent at lower impact angle and higher temperature. High temperature stability of mullite, alumina and oxide layer assists in increasing erosion resistance of coating. The eroded coating surface morphology reveals the brittle mode of material removal. •NiCrAlY/WC-Co/Cenosphere feedstock is successfully deposited using plasma spray coating.•Erosion resistance of the coating is evaluated at 200, 400 and 600°C.•Erosion resistance of coating is 71% much higher than MDN 321 steel substrate at elevated temperatures.•High temperature stability of constituents and oxide layer formation improves the erosion resistance considerably.