Chandramouli, T.V.Joladarashi, S.Ramesh, M.R.Rahman, M.R.2026-02-032025Journal of Materials Engineering and Performance, 2025, 34, 11, pp. 10323-1033810599495https://doi.org/10.1007/s11665-024-09762-3https://idr.nitk.ac.in/handle/123456789/20236Fe-based (stainless steel 316L) coatings are widely employed in the aerospace, chemical processing, petrochemical, and marine industries owing to their low and stable price, excellent corrosion resistance, and durability. However, at elevated temperatures, their performance is limited due to wear. Thus, the current investigation incorporates tungsten carbide (WC-Co) and chromium carbide (Cr<inf>3</inf>C<inf>2</inf>) into the Fe-based coating to enhance its wear resistance at high temperatures. SS316L reinforced by 30% of WC-Co and Cr<inf>3</inf>C<inf>2</inf> by mechanical mixture, then sprayed using high-velocity oxy fuel spraying method. Coating characteristics, such as microstructures and phase analysis, were measured using FESEM/EDS and XRD. Coating density, microhardness, and bond strength were examined by water immersion, Vickers indentation, and ASTM C-633 methods, respectively. A ball-on-disk tribometer was employed to conduct wear examination at various temperatures (25, 300, and 600 °C) and loads (10 and 30 N) against the alumina counter body. The wear rate and friction coefficient of SS316L-30%WC-Co decrease from 25 to 600 °C, while the wear rate of SS316L-30%Cr<inf>3</inf>C<inf>2</inf> increases with temperature up to 300 °C and then decreases at 600 °C. The oxide phase adheres strongly to underlying surfaces forming a protective layer (Cr<inf>2</inf>O<inf>3</inf>, NiWO<inf>4</inf>, Fe<inf>2</inf>O<inf>3</inf>, and NiMO<inf>4</inf>), changing the mode of wear mechanism. At higher temperatures and loads, the coating exhibited oxidation modified adhesive wear, and coatings provide excellent wear resistance along with reduction in friction. This research provides a novel approach for future standardization and evaluation of coatings on metal alloys for industrial applications. © ASM International 2024.AdhesivesAluminaAluminum oxideCalcium carbonateChemical industryChromium compoundsComposite coatingsCorrosion resistanceCorrosion resistant coatingsFrictionHematiteHVOF thermal sprayingIndustrial researchMarine applicationsReinforcementSeawater corrosionSprayed coatingsSteel corrosionTribologyTungsten carbideWear of materialsWear resistanceChemicals processingFe-basedFe-based composite coatingsHigh temperature wearHighest temperatureHVOFIron based compositeMicrostructure mechanical propertiesStainless steel (316L)Tribological propertiesMicrostructure