Further development of iron-based, titanium carbidereinforced thermal spray coatings for wear protectionunder corrosive loads

Thermally sprayed Fe-based coatings are of great importance for many industrial applications due to their high economic efficiency. Through an addition of hard phases, the wear resistance of these coatings can be increased significantly. Thus, coating systems can be optimized as needed. Moreover, the alloy development of the Febased matrix can improve the corrosion resistance of these coatings. In this study, two novel TiC-reinforced Fe-based coatings with a special focus on corrosion resistance were developed using HVAF process. The coatings were subsequently investigated in comparison with well-established coatings made from WCCoCr and Cr3C2-NiCr regarding their microstructure as well as their wear and corrosion resistance. The HVAFsprayed TiC-reinforced coatings feature a very dense microstructure that has a considerably lower oxide content compared to HVOF-sprayed coatings. The novel HVAF-sprayed TiC-reinforced coatings moreover show a comparably high wear resistance compared to the Cr3C2-NiCr reference, while also showing a considerably better corrosion behavior than the HVOF-sprayed TiC/Fe coatings. Overall, they exhibit great potential for wear and corrosion resistance applications.