Slurry erosion performance of HVOF-sprayed WC-based coatings on Al6061 alloy

IF 6.3 2区材料科学 Q2 CHEMISTRY, PHYSICAL

Surfaces and Interfaces Pub Date : 2025-09-30 DOI:10.1016/j.surfin.2025.107777

Vijay C G , Manjunatha K , Santhosh Kumar B M , Girish D P , Dinesh M H

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Abstract

This study examines the wear resistance and erosion resistance of tungsten carbide (WC) coatings sprayed with HVOF on Al6061 alloy. It highlights the impact of coating thicknesses (100 µm and 200 µm) under slurry erosion circumstances. Even though Al6061 alloy has good mechanical qualities, it does not withstand erosion well in high-velocity slurry conditions. Surface hardness and resistance to material loss were greatly increased by the application of WC coatings using the HVOF technique. A dense, homogeneous coating morphology with low porosity was validated by microstructural analysis using SEM and EDAX, guaranteeing excellent adherence to the substrate. In comparison to uncoated Al6061, the 200 µm WC coating reduced weight loss by up to 46 % in the slurry erosion tests, prevailing over the 100 µm coating, which demonstrated a 30 % reduction. The Hardness of Al6061 increased from 80 VHN to 500 VHN with the 200 µm WC coating, representing a remarkable improvement. The study highlights the novelty of systematically optimizing WC coating thickness for superior erosion resistance, with results demonstrating the effectiveness of thicker coatings in mitigating erosion-induced material loss.

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Al6061合金hvof喷涂wc基涂层的液浆侵蚀性能

研究了在Al6061合金表面喷涂HVOF的碳化钨（WC）涂层的耐磨性和耐蚀性。它强调了涂层厚度（100µm和200µm）在泥浆侵蚀情况下的影响。尽管Al6061合金具有良好的机械性能，但在高速泥浆条件下，它不能很好地承受侵蚀。采用HVOF技术制备WC涂层，可大大提高涂层的表面硬度和抗材料损耗能力。通过SEM和EDAX的微观结构分析，验证了致密、均匀、低孔隙率的涂层形貌，保证了与基体的良好粘附性。与未涂覆的Al6061相比，在泥浆侵蚀测试中，200µm WC涂层减少了高达46%的重量损失，优于100µm涂层，减少了30%。200µm WC涂层使Al6061的硬度从80 VHN提高到500 VHN，有了显著的提高。该研究强调了系统优化WC涂层厚度的新颖性，以获得更好的抗侵蚀性，结果表明较厚的涂层在减轻侵蚀引起的材料损失方面的有效性。

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来源期刊

Surfaces and Interfaces Chemistry-General Chemistry

CiteScore

8.50

自引率

6.50%

发文量

753

审稿时长

35 days

期刊介绍： The aim of the journal is to provide a respectful outlet for ''sound science'' papers in all research areas on surfaces and interfaces. We define sound science papers as papers that describe new and well-executed research, but that do not necessarily provide brand new insights or are merely a description of research results. Surfaces and Interfaces publishes research papers in all fields of surface science which may not always find the right home on first submission to our Elsevier sister journals (Applied Surface, Surface and Coatings Technology, Thin Solid Films)