Lowering the thermal energy and increasing the kinetic energy of sprayed particles by newly developed HVAF systems can significantly reduce material decarburization, and increases sliding wear and corrosion resistance of hard metal coatings, making HVAF coatings attractive both economically and environmentally over its HVOFs predecessors. Two agglomerated and sintered feedstock powder chemistries, respectively WC-Co (88/12) and WC-CoCr (86/10/4), with increasing primary carbides grain size from 0.2 to 4.0 microns, have been deposited by the latest HVAF-M3 process onto carbon steel substrates. Respective dry sliding wear behaviours and friction coefficients were evaluated at room temperature via Ball-on-disk (ASTM G99-90) wear tests against Al2O3 counterparts, and via Pin-on-disk (ASTM G77-05) wear tests against modified martensitic steel counterparts in both dry and lubricated conditions. Sliding wear mechanisms, with formation of wavy surface morphology and brittle cracking, are discussed regarding the distribution and size of primary carbides. Corrosion behaviours were evaluated via standard Neutral Salt Spray (NSS), Acetic Acid Salt Spray (AASS), accelerated corrosion test and electrochemical polarization test at room temperature. Optimization of coating tribological properties are discussed regarding the suitable selection of primary carbide size for different working load applications.

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