New Types of Self-Lubricated Thermal Spray Coatings: The Use of Liquid Lubricants in a Metal Matrix

In this work, wire arc spraying is used to produce coatings in which oil-filled capsules are incorporated in the metal matrix. The coatings were deposited on carbon steel substrates using commercially available Zn-Al and FeNiCr alloy wires. The capsules were injected almost radially toward the substrate using an independent slurry feeder. No signs of degradation were observed during spraying and the coatings were able to keep a low coefficient of friction. Wear tracks produced by the steel ball used for friction testing were examined and volume loss was determined based on wear track profiles.