Characterization and evaluation of carbide-based composite coatings for high-temperature wear resistance on Titanium substrate

Abstract

Titanium alloys are used in the automotive and aerospace industries, but perform poorly at high temperatures due to inadequate wear and friction properties. This study investigates Cr<inf>3</inf>C<inf>2</inf>-25%CoNiCrAlY and WC-CoCr coatings applied via High-velocity oxygen Fuel on a titanium-31 substrate. Coatings were evaluated from 200–800?°C under 20?N and 30?N using a ball-on-disc tribometer. Characterization techniques included scanning electron microscope, X-ray diffraction, microhardness, porosity, and bond strength. WC-CoCr coating showed higher hardness and bond strength than Cr<inf>3</inf>C<inf>2</inf>-25%CoNiCrAlY. Both coatings exhibited reduced wear rates until 600?°C, after which the wear rates increased at 800?°C due to enhanced oxidation. The coefficient of Friction decreased with increasing temperature. At 600?°C, oxide phases helped reduce wear and friction. WC-CoCr coating shows better wear resistance than Cr<inf>3</inf>C<inf>2</inf>-25%CoNiCrAlY coating and the substrate. Wear mechanisms changed from abrasive and fatigue at 200?°C to oxidative and adhesive at 800?°C. Volumetric ball loss was higher for WC-CoCr due to its greater hardness. © The Author(s) 2025