Novel suspension route to incorporate graphene nano-platelets in HVAF-sprayed Cr3C2–NiCr coatings for superior wear performance

Graphene nano platelets (GNP) have several attractive properties, including excellent lubricity that can be used to develop wear-resistant coatings. Thermally sprayed chromium carbide–nickel chromium (Cr3C2–NiCr) coatings are widely employed to impart wear resistance to engineering components. This work attempts to improve the wear resistance of high velocity air fuel (HVAF) sprayed Cr3C2–NiCr coatings by incorporating GNP using a hybrid approach in which Cr3C2–NiCr (powder) and GNP (suspension) are co-axially injected. Two different powder-to-suspension delivery ratios were employed in this study that utilizes a liquid feedstock in tandem with a HVAF system. Furthermore, for comparison, a pure (without graphene) Cr3C2–NiCr reference coating was deposited by the HVAF process using identical spray parameters. The as-sprayed coatings were characterized for their microstructure and phase constitution by SEM/EDS and X-Ray Diffraction. Mechanical properties such as hardness and fracture toughness were evaluated using micro-indentation technique. The hybrid coatings were subjected to dry sliding wear tests and wear performance was compared with reference Cr3C2–NiCr. The GNP incorporated hybrid coatings exhibited lower CoF and lower wear rates than the reference Cr3C2–NiCr coating. Post wear SEM/EDS analysis revealed different wear mechanisms predominant in the investigated coatings. Utilizing the above as a case study, this work provides key insights into a new approach to produce GNP incorporated coatings for mitigating wear.

Abstract licence: CC BY-NC

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