Comparison of dry sliding wear behavior of plasma sprayed FeCr slag coating with Cr2O3 and Al2O3-13TiO2 coatings

Abstract

The microstructure and dry sliding wear performance of thermally sprayed FeCr slag coating were evaluated in comparison with those of commercially available Al2O3-13TiO(2) and Cr2O3 ceramic coating powders to assess the applicability of FeCr slag (FS) powder, fabricated from industrial waste, as a ceramic top-coating material against wear. Ceramic top coats and underlying NiCoCrAlY bond coats were deposited on AISI 316L samples via atmospheric plasma spraying (APS), and their tribological properties were assessed using a ball-on-disc test rig at room temperature. As a result, FS coating exhibited the lowest worn volume, although it has the lowest surface hardness. Tribolayer formation was observed on the surface of the samples which were subjected to dry sliding wear tests. Delamination type wear is the dominant wear mechanism for Cr2O3 and FS coatings, whereas local spallation areas arising from plastic deformation were observed on the surface of Al2O3-13TiO(2) coatings. The results suggested the applicability of FS powder as a candidate ceramic top coating material against wear.