Optimization of WC-Based HVAF-Sprayed Coatings for Alternative to Hard Chromium: Role of Carbides, Grain Size, and Mean Free Path in Coating Wear and Corrosion Properties

Two agglomerated and sintered powders, WC-Co and WC-Co-Cr, were deposited by HVAF spraying and evaluated based on material decarburization, coating porosity, and microhardness. The role of carbide grain size, contiguity, and binder mean free path is investigated with respect to coating microstructure and wear and corrosion resistance.