Tribological Performance of Fe-Based Composite Coatings Under Elevated Temperature Conditions

Abstract

The present study investigated the tribological performance of Fe-based coatings reinforced with carbides onto a maraging steel substrate using the HVOF spray technique. These materials are widely used in manufacturing various components in the aerospace and energy sectors. Commercially available SS316L and 17-4PH are reinforced with WC–Co feedstock powders to deposit these composite coatings on maraging steel substrate. The dry sliding wear tests were conducted using the ball-on-disc tribometer at varying temperatures (25 and 300 °C) with 10 N normal load using an alumina ball (Al<inf>2</inf>O<inf>3</inf>) as the counter body. The study includes micro-hardness, porosity, density, bond strength, and surface roughness of the coatings. The samples subjected to wear testing were analyzed using SEM/EDS and XRD techniques, and the wear scar volume was measured using a 3D profilometer to calculate the volume metric loss. The wear rate of SS316L30%WC–Co is 64.46% lower than that of 17-4PH30%WC–Co at room temperature and 67.33% lower at 300 °C under a load of 10 N. At room temperature, the worn surface exhibited abrasive wear, while at 300 °C, adhesive wear and oxidative wear were observed owing to the formation of protective layers. Therefore, SS316L-30%WC–Co demonstrates superior wear resistance compared to 17-4PH-30%WC–Co and offers enhanced mechanical strength, particularly in challenging environments. The deposition of these coatings effectively protects the maraging steel substrate. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.