Residual, Corrosion & Tribological Behavior of HVOF Sprayed Sustainable Temperature-Dependent Carbon-Based Hybrid Composite Coating

Abstract

At present, cost-effective coatings that cause less pollution are in great demand; to decrease frictional losses, carbon-based hybrid composite coatings have been developed using a high-velocity oxy-fuel (HVOF) spray process. The microstructural, tribological, corrosion, and mechanical properties of these coatings have been evaluated using high-resolution X-ray diffraction (HRXRD), field emission scanning electron microscopy-Energy dispersive X-ray Spectroscopy (FESEM-EDS), Raman spectrum, Vickers micro-hardness tester, µ-360 cos(α) residual stress analyser, corrosion tester, and high temperature tribometer. The residual stress, corrosion and tribological behaviour at high temperatures were investigated using a pin-on-disc high-temperature tribometer. The tribological performance was evaluated using a high-temperature tribometer, and the experimental result shows that a coefficient of friction (COF) varies from 0.12 to 0.52, while wear results were in the range of 45 µm to 120 µm, as the test condition of temperature ranging from 50 °C to 350 °C, load from 60 N to 90 N and sliding velocity from 0.1 m/s to 0.4 m/s respectively. The experimental results of corrosion testing show that the mass loss decreases from 0.10 g to 0.04 g, when samples were dipped for 1 h; when the samples were dipped for 8 h, the mass loss of hybrid composite coating varied from 0.12 g to 0.045 g. The tribological test showed a 78.9 % increase in micro-hardness, a 78 % decrease in residual stress, and 60 % and 62.5 % decreases in mass loss due to corrosion at 1 h and 8 h, respectively, a 76.9 % decrease in COF and 62.5 % reduction in the wear at test condition of 350 ºC temperature, a sliding velocity of 0.4 m/s and 90 N load.