One of the most important uses of HVOF thermal sprayed CrC-NiCr coatings is for wear resistance. In this work Cr3C275-NiCr25 coatings were obtained by high-velocity oxy-fuel system from three agglomerated feedstock powders with various powder size distributions (- 30, -10 and –5 µm). The powders were agglomerated, sintered, plasmafused and crushed, in order to increase their density. The coating microstructures were characterised by SEM microscopy. Differences in coating roughness have been determined by profilometry. The ultra-microindentation technique was applied to measure the hardness and the elasto-plastic properties of the coatings. Experiments using a tribometer (pin on disc configuration) under lubricated and dry conditions have been performed in order to evaluate the friction and wear properties of the different coatings. It was found that the coatings obtained with the lowest feedstock powder size presented the best sliding wear resistance under all the conditions. This fact could be explained in terms of differences of cohesion between the carbide particles and the binder phase. The lower feedstock powder presents a lower carbide particle size that involves a better distribution and cohesion of the chromium carbide with the NiCr binder phase. This fact leads a minor production of “third body” hard particles in the wear tests that influenced quite considerably in the final wear rate of the studied coatings.

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