Microstructure and Wear Behavior of MMC Coatings Deposited by Plasma Transferred Arc Welding and Thermal Flame Spraying Processes

In this study, two erosion protection MMC coatings with WC particles were deposited by the plasma transferred arc (PTA) welding. One of the coatings with tungsten carbide WC in the NiBSi matrix (WC/NiBSi), and the second coating WC in NiCrBSi matrix (WC/NiCrBSi) was deposited by the flame spray process on the same substrate material S235JR steel. Experiments were performed using a gas blast sand erosion test facility with high-velocity erodent particles impact (approximately 100 m/s) at different particle impact angles (20°–45°), with an objective to study erosion wear characteristics and mass loss of two MMC coatings. Microstructural characterization of MMC coatings was done by scanning electron microscope equipped with energy-dispersive X-ray spectroscopy, whereas X-ray diffraction analysis was used for identification of present phases. The hardness of coatings was determined by Vickers hardness measurements. WC/NiBSi obtained by the PTA process shows superior hardness and erosion properties.