Medabalimi, S.Ananthu, M.R.Gudala, S.Ramesh, M.R.2026-02-042023Journal of Materials Engineering and Performance, 2023, 32, 19, pp. 8612-862410599495https://doi.org/10.1007/s11665-022-07756-7https://idr.nitk.ac.in/handle/123456789/21712HVOF-processed coatings are chemically inhomogeneous and are not metallurgically bonded to the substrate. As a result, components coated with HVOF experience considerable material degradation during sliding wear. Microwave hybrid heating (MHH) is a novel surface modification technique for modifying the as-sprayed properties of the coating. Hence, this paper investigates and compares the wear and frictional behavior of HVOF as-sprayed coatings against MHH samples of WC-CrC-Ni and WC-Co/NiCrFeSiB coatings at elevated temperatures. MHH had a significant impact on wear rate and coefficient of friction by optimizing the porosity, integrated oxide phases and intersplat cohesion strength of the coatings. A modified domestic oven was used to perform MHH on HVOF-coated samples for 5 min at 1200 °C. Wear tests were performed using a pin-on-disk tribometer from room temperature to 200, 400, and 600 °C with Al<inf>2</inf>O<inf>3</inf> disk as a counterface. SEM/EDS and XRD were utilized to examine the microstructural characterization of the coatings and substrate. Both the coatings showed higher wear resistance than the substrate at all temperatures. The WC-Co/NiCrFeSiB coating produced an oxide layer on the worn surfaces and integrated WC, CoWO<inf>4</inf>, and Fe<inf>2</inf>SiO<inf>4</inf> splats, enhancing wear resistance. The MHH WC-CrC-Ni coating formed Cr<inf>2</inf>O<inf>3</inf> and NiWO<inf>4</inf> phases on the worn surfaces, increasing the intersplat cohesion strength between matrix and carbide splats, lowering the overall wear rate. After MHH, the wear rate of a substrate and WC-CrC-Ni coating was 3.5 and 1.12 times more at room temperature and 8.07 and 2.92 times more at 600 °C than WC-Co/NiCrFeSiB coating. © 2022, ASM International.AdhesivesAluminaAluminum oxideCarbidesChromium compoundsCobalt compoundsHVOF thermal sprayingIron compoundsNickel compoundsOxygenSprayed coatingsWear of materialsWear resistanceCohesion strengthHigh temperature wearHigh-temperature frictionHighest temperatureHVOFMicrowave hybrid heatingNi coatingWear behaviorsWear-rateWorn surfaceFriction