The influence of tungsten carbide particle size on the characteristics of metalloceramic WC/Fe-Ni-Al coatings
- Authors: Burkov A.A.1, Dvornik M.I.1, Kulik M.A.1, Bytsura A.Y.1
-
Affiliations:
- Khabarovsk Federal Research Center FEB RAS
- Issue: Vol 27, No 3 (2025)
- Pages: 221-235
- Section: Articles
- URL: https://ogarev-online.ru/1994-6309/article/view/308851
- DOI: https://doi.org/10.17212/1994-6309-2025-27.3-221-235
- ID: 308851
Cite item
Abstract
Introduction. The granulometry (particle size distribution) of the starting powders significantly influences the hardness and strength of compacted tungsten carbide (WC) metalloceramic materials, but this effect has not been extensively studied in the context of WC/Fe-Ni-Al coatings. The purpose of this work is to investigate the influence of the granulometry of the starting WC powder introduced into the non-localized electrode on the kinetics of mass transfer, chemical composition, cross-sectional microstructure of WC/Fe-Ni-Al coatings, and their corrosion and tribological properties. Methods. WC/Fe-Ni-Al coatings were deposited on 45 steel substrates using the electrospark deposition (ESD) method with a non-localized electrode. The electrode comprised iron granules (Ø = 4 mm), Ni and Al powders, and WC powders with varying particle sizes. X-ray diffraction (XRD) analysis revealed that the coatings consisted of tungsten carbide, tungsten semicarbide (W?C), intermetallic phases (Al??Fe??), ferronickel (FeNi), and body-centered cubic (BCC) phases (AlNi, AlFe). Results and discussion. It was determined that, with an increase in the WC powder particle size fraction in the electrode, the coating matrix composition became enriched with aluminum, while the iron concentration decreased from 60 to 30 at.%. The lowest values for hardness, wear resistance, and oxidation resistance were observed for the sample obtained using WC nanopowder. The microhardness of the coating surface ranged from 4.39 to 9.16 GPa. The oxidation resistance of the coated samples at 700 °C increased monotonically with increasing WC powder particle size. The study found that the use of WC powder with a particle size fraction of 20 to 40 µm resulted in the best performance in terms of hardness, wear resistance, and oxidation resistance of the WC/Fe-Ni-Al coatings at 700 °C. The application of these coatings increased the oxidation resistance of 45 steel by 11.6 times and wear resistance by 44 to 80 times, suggesting their potential for use in high-intensity applications.
About the authors
Alexander A. Burkov
Khabarovsk Federal Research Center FEB RAS
Email: burkovalex@mail.ru
ORCID iD: 0000-0002-5636-4669
SPIN-code: 3359-0076
Scopus Author ID: 56120881300
ResearcherId: E-8844-2016;
Ph.D. (Physics and Mathematics), Head of Laboratory
Russian Federation, 153 Tihookeanskaya st., Khabarovsk, 680042, Russian FederationMaxim I. Dvornik
Khabarovsk Federal Research Center FEB RAS
Email: Maxxxx80@mail.ru
ORCID iD: 0000-0002-1216-4438
SPIN-code: 8132-8414
Scopus Author ID: 56631651600
ResearcherId: AAG-5481-2021
Ph.D. (Engineering), Senior researcher
Russian Federation, 153 Tihookeanskaya st., Khabarovsk, 680042, Russian FederationMaria A. Kulik
Khabarovsk Federal Research Center FEB RAS
Author for correspondence.
Email: marijka80@mail.ru
ORCID iD: 0000-0002-4857-1887
SPIN-code: 5300-8010
Scopus Author ID: 55925456600
Junior researcher
Russian Federation, 153 Tihookeanskaya st., Khabarovsk, 680042, Russian FederationAlexandra Yu. Bytsura
Khabarovsk Federal Research Center FEB RAS
Email: Alex_btsr@mail.ru
ORCID iD: 0009-0005-4750-7970
SPIN-code: 6032-6323
Scopus Author ID: 58120983400
ResearcherId: KSM-2887-2024
Junior researcher
Russian Federation, 153 Tihookeanskaya st., Khabarovsk, 680042, Russian FederationReferences
- High-temperature corrosion characterization of Ni-Al laser cladding: The effect of Al content and Fe / X. Wang, Z. Liu, K. Cheng, J. Li, H. Ning, J. Mao // Journal of Thermal Spray Technology. – 2024. – Vol. 33 (5). – P. 1417–1439. – doi: 10.1007/s11666-024-01782-8.
- Study on the microstructure and properties of a laser cladding Fe–Ni–Al coating based on the invar effect / Z. Wang, J. Zhang, F. Zhang, C. Qi // Scientific Reports. – 2024. – Vol. 14 (1). – P. 11685. – doi: 10.1038/s41598-024-62306-6.
- Microstructure, mechanical properties and wear of Ni–Al–Fe alloys / P.R. Munroe, M. George, I. Baker, F.E. Kennedy // Materials Science and Engineering: A. – 2002. – Vol. 325 (1–2). – P. 1–8. – doi: 10.1016/S0921-5093(01)01403-4.
- Structure and oxidation resistance of flame sprayed Fe–Ni–Al coating / A.S.I. Datu-Maki, Ciswandi, B. Hermanto, S.A. Saptari, T. Sudiro // Journal of Physics: Conference Series. – 2019. – Vol. 1204 (1). – P. 012128. – doi: 10.1088/1742-6596/1204/1/012128.
- Optimization and experimental investigation on AA6082/WC metal matrix composites by abrasive flow machining process / R. Manikandan, P. Ponnusamy, S. Nanthakumar, A. Gowrishankar, V. Balambica, R. Girimurugan, S. Mayakannan // Materials Today: Proceedings. – 2023. – doi: 10.1016/j.matpr.2023.03.274.
- Microstructure and tribology of cold spray additively manufactured multimodal Ni-WC metal matrix composites / S.A. Alidokht, L. Wu, S. Bessette, R.R. Chromik // Wear. – 2024. – Vol. 538. – P. 205218. – doi: 10.1016/j.wear.2023.205218.
- Effect of WC mass fraction on the microstructure and frictional wear properties of WC/Fe matrix composites / Z. Liao, X. Huang, F. Zhang, Z. Li, S. Chen, Q. Shan // International Journal of Refractory Metals and Hard Materials. – 2023. – Vol. 114. – P. 106265. – doi: 10.1016/j.ijrmhm.2023.106265.
- Microstructures and high-temperature wear behavior of NiAl/WC-Fex coatings on carbon steel by plasma cladding / J. Yuan, Q. Wang, X. Liu, S. Lou, Q. Li, Z. Wang // Journal of Alloys and Compounds. – 2020. – Vol. 842. – P. 155850. – doi: 10.1016/j.jallcom.2020.155850.
- Abreu-Castillo H.O., d’;Oliveira A.S.C.M. Challenges of nanoparticle-reinforced NiAl-based coatings processed by in situ synthesis of the aluminide // The International Journal of Advanced Manufacturing Technology. – 2024. – Vol. 134 (3–4). – P. 1547–1561. – doi: 10.1007/s00170-024-14162-x.
- Бурков А.А. Использование гранул Ni и Al и порошка WC для электроискрового нанесения металлокерамических покрытий // Известия высших учебных заведений. Порошковая металлургия и функциональные покрытия. – 2025. – Т. 19, № 2. – С. 62–72. – На англ. яз. – doi: 10.17073/1997-308X-2025-2-62-72. – EDN NPZJWX.
- Advancements in electrospark deposition (ESD) technique: A short review / C. Barile, C. Casavola, G. Pappalettera, G. Renna // Coatings. – 2022. – Vol. 12 (10). – P. 1536. – doi: 10.3390/coatings12101536.
- Николенко С.В., Верхотуров А.Д. Новые электродные материалы для электроискрового легирования. – Владивосток: Дальнаука, 2005. – 219 с. – ISBN 5-80444-0404-0.
- Burkov A.A., Kulik M.A. Wear-resistant and anticorrosive coatings based on chrome carbide Cr7C3 obtained by electric spark deposition // Protection of Metals and Physical Chemistry of Surfaces. – 2020. – Vol. 56. – P. 1217–1221. – doi: 10.1134/s2070205120060064.
- Dvornik M., Mikhailenko E. The influence of the rotation frequency of a planetary ball mill on the limiting value of the specific surface area of the WC and Co nanopowders // Advanced Powder Technology. – 2020. – Vol. 31 (9). – P. 3937–3946. – doi: 10.1016/j.apt.2020.07.033.
- Dvornik M.I., Zaytsev A.V. Research of surfaces and interfaces increasing during planetary ball milling of nanostructured tungsten carbide/cobalt powder // International Journal of Refractory Metals and Hard Materials. – 2013. – Vol. 36. – P. 271–277. – doi: 10.1016/j.ijrmhm.2012.10.004.
- Бурков А.А. Получение аморфных покрытий электроискровой обработкой стали 35 в смеси железных гранул с CrMoWCBSi порошком // Обработка металлов (технология, оборудование, инструменты). – 2019. – Т. 21, № 4. – С. 19–30. – doi: 10.17212/1994-6309-2019-21.4-19-30.
- Effect of spray powder particle size on the bionic hydrophobic structures and corrosion performance of Fe-based amorphous metallic coatings / Y.C. Li, W.W. Zhang, Y. Wang, X.Y. Zhang, L.L. Sun // Surface and Coatings Technology. – 2022. – Vol. 437. – Р. 128377. – doi: 10.1016/j.surfcoat.2022.128377.
- Almond E.A., Gee M.G. Results from a UK interlaboratory project on dry sliding wear // Wear. – 1987. – Vol. 120 (1). – P. 101–116. – doi: 10.1016/0043-1648(87)90136-0.
- Kennedy F.E., Lu Y., Baker I. Contact temperatures and their influence on wear during pin-on-disk tribotesting // Tribology International. – 2015. – Vol. 82. – P. 534–542. – doi: 10.1016/j.triboint.2013.10.022.
- Characterization of wear rate of Al-12 wt% Si alloy based MMC reinforced with ZrO2 particulates / M. Nataraja, G. Balakumar, N. Santhosh, M.R. Naik // Materials Research Express. – 2024. – Vol. 11 (3). – P. 036522. – doi: 10.1088/2053-1591/ad3468.
- Chivavibul P., Watanabe M., Kuroda S. Effect of microstructure of HVOF-sprayed WC-Co coatings on their mechanical properties // Thermal Spray. – 2007. – P. 1212. – doi: 10.31399/asm.cp.itsc2007p0297.
- The influence of microstructure on tribological properties of WO3 thin films / O.D. Greenwood, S.C. Moulzolf, P.J. Blau, R.J. Lad // Wear. – 1999. – Vol. 232 (1). – P. 84–90. – doi: 10.1016/S0043-1648(99)00255-0.
- Jayashree P., Turani S., Straffelini G. Effect of velocity and temperature on the dry sliding behavior of a SiC-Graphite composite against WC-CoCr and WC-FeCrAlY HVOF coatings // Wear. – 2021. – Vol. 464. – P. 203553. – doi: 10.1016/j.wear.2020.203553.
- Ameen H.A., Hassan K.S., Mubarak E.M.M. Effect of loads, sliding speeds and times on the wear rate for different materials // American Journal of Scientific and Industrial Research. – 2011. – Vol. 2 (1). – P. 99–106. – doi: 10.5251/ajsir.2011.2.1.99.106.
Supplementary files
