Improvement of the High Temperature Wear Resistance of Laser Cladding Nickel-Based Coating: A Review
Abstract
:1. Introduction
2. Ceramic Phase
2.1. WC
Ref. | Substrate | Matrix | Ceramic Phase | Key Findings | Tribological Testing Process, Parameters |
---|---|---|---|---|---|
Zhou, 2011 [26] | 1Cr18Ni 9Ti | NiCrBSi | WC | Coatings produced by supplementing WC powder with NiCrBSi display greater high temperature abrasion resistance than NiCrBSi coatings | A THT07-135 pin-on-disk tribometer; Si3N4 ball (diameter 6 mm); Load: 5 N; Temperature: 25, 500 °C; Sliding speed 300 mm/s; Sliding distance: 500 m |
Guo, 2010 [30] | pure Ti discs | NiCrBSi | WC | Under similar circumstances, the abrasion rate of the NiCrBSi/WC-Ni composite coating is around 24–47 times lower than that of the pure Ti substrate | A THT07-135 pin-on-disk tribometer; Si3N4 ball (6 mm). Temperatures: 300 °C, 500 °C; Load: 5 N; Sliding speed: 300 mm/s; Sliding distance: 500 m |
Wang, 2013 [31] | 4Cr14Ni14NW2Mo | NiCrBSi | WC, CeO2 | Ni21 + 20%WC + 0.5%CeO2 coating microstructure was effectively refined and the coating presented a relatively well-abrasive behavior | A MG-200 high speed and temperature wear test machine. Grinding ring: heat-resistant cast iron; Temperature: RT (Rome temperature), 250, 450 and 650 °C; Load: 300 N; Velocity: 25 r/s; Load time: 3~3.5 min |
2.2. TaC
2.3. Other Ceramic Phase
Ref. | Substrate | Matrix | Ceramic Phase | Key Findings | Tribological Testing Process, Parameters |
---|---|---|---|---|---|
Zang, 2015 [38] | 20Cr2Ni4A | Ni45 | NiCr-Cr3C2 | NiCr–Cr3C2 coating has a better abrasive rate and lower COF | A ball-on-plate friction test; Temperatures: 20, 100 and 300 °C using; SiC ball (d = 10 mm); Load: 3 kg; The stroke: 1000 μm; frequency: 50 Hz Time: 30 min |
Guo, 2013 [40] | pure Ti discs | NiCoCrAlY alloy powder | ZrB2 | The addition of ZrB2 as a hard ceramic phase to support and protect the substrate during the wear process, resulting in only slight wear marks on the surface in the friction test | A SRV-IV friction and wear tester. Si3N4 balls (d = 1 cm); Temperature: 20, 100, 300 and 500 °C; Load: 40 N; frequency: 15 Hz; Time: 15 min |
Sun, 2022 [41] | Q235 low carbon steel | Ni60AA | Cu, CuMo, CuMoW | The additive of Cu refines the organization of the coating and results in the formation of NiCu solid solution. Resists wear and lubrication | MMQ-02G; The zirconia ball (4 mm); Temperature: RT, 600 °C; Time: 30 min; Load: 30 N; Frequency: 1 Hz |
3. Solid Lubricants
3.1. Lamellar Solids
Ref. | Substrate | Matrix | Ceramic Phase | Key Findings | Tribological Testing Process, Parameters |
---|---|---|---|---|---|
Torres, 2018 [50] | stainless steel | NiCrBSi | MoS2, WS2, Ag, Cu | The high temperature wear resistance of the coating decreases after the addition of Cu and Ag | AISI 52,100 bearing balls with a diameter of 10 mm; Load: 50 N. Temperature: RT, 150, 300, 400, 600 °C; Wear time: 900 s; Stroke length: 2 mm |
Kumar, 2023 [51] | stainless steel | NiCrBSi | Ni3S2, CuS, Bi2S3 | The coating retains high hardness at high temperatures, but the friction coefficients all become unstable | Ball-on-plate configuration; Load: 50 N; Frequency and stroke: 25 Hz and 0.2 cm; Sliding speeds of 10 cm/s. Time: 900 s; Temperature: 25, 400, 600 °C |
Dilawary, 2018 [54] | AISI 4140 steel | NiCrBSi | Mo | MoO2 can not only enhance the hardness but also act as a solid lubricant to decrease the wear coefficient of the coating | A ball-on-disc configuration; Load: 3 N; Contact pressure: 1.0 GPa; Temperatures: RT, 300, 500 and 700 °C |
Sun, 2022 [41] | Q235 | Ni60AA | Cu, CuMo, CuMoW | Mainly due to the fine and uniform microstructure and the formation of NiCu solid solution phase, the coating with the addition of Cu exhibits excellent wear resistance | MMQ-02G; The zirconia ball with a radius of 4 mm; Temperature: RT, 600 °C; Time: 30 min; Load: 30 N; Frequency: 1 Hz |
Liu, 2021 [56] | 304 stainless steel | Ni60 | Ti3SiC2 | Ti3SiC2 synergizes with Ni60 oxide film for better lubrication performance at high temperatures | Si3N4 ball (diameter: 5 mm); Load: 5 N; Time: 30 min; The rotation velocity is 560 r/min. Temperature: 25, 600 °C |
Ref. | Substrate | Matrix | Ceramic Phase | Key Findings | Tribological Testing Process, Parameters |
---|---|---|---|---|---|
Zhang, 2019 [60] | Ti6Al4V | Ni60 | h-BN | The h-BN particles were decomposed to synthesize TiB and TiN in situ in the melt pool to resist wear. The metal oxides produced at high temperatures act as a lubricant | A ball-on-disk type friction and wear test machine; Si3N4 ceramic balls of Φ 6 mm; Rate: 5 Hz; Load: 5 N; Duration: 60 min |
Lu, 2016 [61] | Ti6Al4V | NiCrBSi | h-BN | Most of the h-BN decompose to produce TiB2, which boosts the hardness of the coating. The residual h-BN acts as a lubricant during friction | A ball-on-disk tribo-meter; Temperature: 20, 300, 600 °C; The counter-body was a Si3N4 ceramic ball (d = 4 mm); Duration: 30 min |
Zhang, 2008 [62] | 1Cr18Ni9Ti | Nickel powder | h-BN | At lower temperatures, coating wear resistance increases with increasing temperature; in the range of 600–800 °C, coating wear resistance decreases due to the decrease in hardness. | A GWY-2000 ball-on-disc friction and wear tester; Si3N4 ceramic (d = 10); Load: 100 N; Sliding speed: 0.226 m/s; Duration: 20 min |
Liu, 2020 [63] | TC4 | Ni60 | TiN, WS2 + h-BN | The addition of WS2 + h-BN and TiN increased the average microhardness of the coating by 1.3–1.7 times, and the friction coefficient of the coating was stable | A pin-and-disc friction and wear tester. Duration: 30 min; Load: 50 N, the speed was 100 rpm, the grinding radius: 3 mm. WC ball (d = 9.5 mm) |
Zhao, 2021 [67] | Q235 | Ni60 | Cu/h-BN + MoO3 | The breakdown of c-BN boosts the bond strength between Cr(Mo)B and the substrate. At the same time, h-BN provides a low coefficient of friction over a broad range of temperatures | A dry sliding pin-on-disk device. Al2O3 balls (d = 5 mm); load: 3 kg; rotating speed: 50 rpm; The rotation diameter 0.1 cm; friction duration: and 0.5 h |
Liu, 2022 [70] | 45# steel | Ni60 | Cu | Cu plays the friction transfer film and oxidation double-layer self-lubrication. Ni60-5 wt.%Cu composition of the coating, the coefficient of friction at 600 °C is 0.267 | High temperature tribometer with Si3N4 ceramic balls on disk using Φ 6 mm; load: 5 N; time: 30 min; temperature: RT, 600 °C. |
3.2. Soft Metals
4. Conclusions
- (1)
- The wear resistance of the coating is highly correlated with the hardness. The addition of a hard ceramic phase can make the coating maintain a relatively high hardness under the high temperature condition and thus boost the high temperature wear resistance of the coating. Compared with a wide variety of added phases at room temperature, the hard ceramic phase added to enhance high temperature wear resistance is relatively single. The improvement effect of a large number of hard ceramic phases on high temperature wear resistance is yet to be explored. Future work could revolve around a wider range of hard ceramic phases to improve the high temperature wear resistance of coatings. At the same time, the synergistic effect of various hard phases can be studied. In addition, the effects of an electric field, magnetic field, vibration and other auxiliary treatments on high temperature wear resistance of nickel-based coatings can be systematically studied.
- (2)
- The interplanar cohesive bonds between the lamellar solid surfaces are weak, and the lamellar structure plays a self-lubricating role under low shear stress conditions. Soft metal’s own low shear strength and strong ductility in the relatively hard contact surface form a thin layer of soft friction layer. These two types of solid lubricants in high temperature conditions can play a useful role in improving the wear resistance of nickel-based coatings.
- (3)
- The existing lubricant takes effect in a narrow range, and the wear resistance of the coating decreases remarkably after exceeding the applicable temperature range. Future solutions: one is to develop new high temperature lubricating materials with better lubrication effect and wider temperature ranges. The other is through the synergistic effect of multiple lubricants, the high temperature wear resistance of the coating can be maintained at a high level.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Ref. | Substrate | Matrix | Ceramic Phase | Key Findings | Tribological Testing Process, Parameters |
---|---|---|---|---|---|
Li, 2017 [35] | Ti6Al4V | NiCrBSi | TaC | The addition of TaC obviously refines the microstructure of the coating; the hardness and high temperature wear resistance of the coating are improved | A GHT-1000E high-temperature tribometer; Hard Si3N4 ceramic balls (d = 4 mm); Load: 10 N; Temperature: 600 °C; Tliding speed: 0.188 m/s |
Yu, 2021 [36] | Medium carbon steel | NiCrBSi | Ta | TaC synthesized in situ has higher hardness and thermal stability, stronger bonding at TaC/substrate intersection | A pin-on-disc tribometer; Al2O3 disk; Load: 90 N; Temperature: 25, 300 °C, 600 and 700 °C; Sliding speed: 790 m m/s; Time: 60 min |
Yu, 2022 [37] | Inconel 625 Nickel-based alloy | Ni-Al-Cr | Ta, C powder | TaC grains withstand the burden and prevent micro-cutting of debris. Ta inhibits the growth of Al2O3 and accelerates the sintering of the oxide layer, forming a dense oxide layer over the wear surface | A pin-on-disc tribometer; Load: 60 N; Temperatures: RT, 300 °C, 550 °C and 700 °C; Time: 1 h; Sliding speed: 0.105 m/s |
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Liu, Y.; Wang, K.; Fu, H. Improvement of the High Temperature Wear Resistance of Laser Cladding Nickel-Based Coating: A Review. Metals 2023, 13, 840. https://doi.org/10.3390/met13050840
Liu Y, Wang K, Fu H. Improvement of the High Temperature Wear Resistance of Laser Cladding Nickel-Based Coating: A Review. Metals. 2023; 13(5):840. https://doi.org/10.3390/met13050840
Chicago/Turabian StyleLiu, Yingpeng, Kaiming Wang, and Hanguang Fu. 2023. "Improvement of the High Temperature Wear Resistance of Laser Cladding Nickel-Based Coating: A Review" Metals 13, no. 5: 840. https://doi.org/10.3390/met13050840