3D Wear Analysis of Thermal Spray Coatings

This study investigates the wear resistance of WC-FeCSiMn coatings deposited on 3D surfaces by two-wire arc spraying. Wear behavior was evaluated by means of pin-on-disc testing, pin-on-rotating tube testing, and a method in which a robot arm moves a pin over test specimens with arbitrary surface geometries. Residual stresses were determined by incremental hole drilling and were found to have a dependency on substrate geometry. After wear testing, a 3D profilometer determined wear volume and coating surfaces were examined by SEM. The results indicate that wear resistance is strongly influenced by the geometry of the substrate.