Effect of Atmospheric Plasma Spraying Power on Microstructure and Properties of WC-(W,Cr)2C-Ni Coatings

WC-(W,Cr)(2)C-Ni coatings were prepared by atmospheric plasma spraying (APS) with different spraying powers. The effect of spraying power on microstructure, phase composition, hardness, fracture toughness, and oscillating dry friction and wear behaviors of the coatings were studied. Simultaneously, the microstructure and properties of the as-sprayed coatings were compared with those of WC-17Co coating prepared under the optimal spraying power. It was found that spraying power had significant effect on the molten degree of feedstock powder and phase composition as well as microstructure and properties of WC-(W,Cr)(2)C-Ni coatings. WC-(W,Cr)(2)C-Ni coating deposited at a moderate spraying power of 22.5 kW had the highest fracture toughness and the best wear resistance. WC-17Co coating obtained under the moderate spraying power had poor fracture toughness and wear resistance. Moreover, the four kinds of coatings were all dominated by subsurface cracking and removal of materials when sliding against Si3N4 ball under unlubricated conditions.