This work evaluates the potential of using a plasma spray process to introduce SiC into zirconia diboride ceramic coatings. Controlling the spraying of the ultra-refractory compound ZrB 2 is the first challenge as it represents the matrix in which SiC particles will reside. To that end, the experiments focus on spraying parameters that influence the plasma jet and the nature of the precursor feedstock. The results show that ZrB 2 coatings containing controlled amounts of SiC can be obtained through high-energy suspension plasma spraying. The ZrB 2 -SiC coatings will be evaluated in a high-temperature oxidative environment in future work.

In this study, MoB-CoCr composite coatings are deposited on low-carbon steel substrates by HVOF spraying and salt spray tests are conducted to qualitatively evaluate coating density. Test samples with optimized dense coatings showed no rust after 300 hours in a salt spray. Samples with porous coatings, on the other hand, showed signs of rust after just 24-48 hours. Test samples protected by the dense composite coatings, as confirmed by salt spray testing, were undamaged after 90 days of immersion in a Zn-0.2%Al galvanizing bath at 460 °C.

This study assesses the potential of kinetic-spray coatings for dealing with the effects of soldering and erosion on aluminum casting dies. In the experiments, molybdenum-boride cermet and cobalt-based alloy powders are cold sprayed onto SKD61 substrates. Coating microstructure is assessed via SEM and XRD analysis and several mechanical properties are measured. In order to evaluate soldering resistance, the coatings are immersed in a molten aluminum bath. Although cold-sprayed CoCrNiWC exhibited high coating density and low porosity, its soldering resistance was significantly lower than that of MoB-NiCr. The boride cermet coating not only exhibited superior soldering resistance, but also higher hardness, bond strength, and wear resistance. However, its deposition efficiency needs further improvement.

The boride cermets composed of M3B2 (M: metal)-system complex borides and metals, have attained superiority over carbide cermets in various mechanical properties. However, their sintered materials have been put into only limited use due to the cost. Therefore, thermal spray coating of the boride cermets was investigated. The powders for thermal spray were prepared by low temperature sintering, and the spraying was performed by HVOF. Microstructure of the sprayed layer was finer, and its hardness was superior to that of a body sintered in vacuum having the same composition. It is clarified that these boride cermet coated layers have outstanding sliding properties. Instantly frictional stress between this boride cermet layer and glass at high temperature is extremely low compared to other materials.

A novel thermal spray material of MoB/CoCr with high durability in molten aluminum and/or zinc alloys has been developed to utilize for die casting parts and for galvanizing bath parts. The durability of the MoB/CoCr coatings prepared by high velocity oxy-fuel (HVOF) spraying has been investigated using a molten-metal immersing tester. It has been found that durability of the MoB/CoCr coating in the molten aluminum and Al-45%Zn alloys is much higher than that of the conventional surface treatments, such as physical vapor deposition, nitridation and spray coatings of conventional materials, such as WC/12%Co, WC/10%Co/4%Cr, Cr 3 C 2 /NiCr, Al 2 O 3 and ZrO 2 -8%Y 2 O 3 . Preservation of the crystal structure and no decrease in coating thickness due to dissolution or delamination of the MoB/CoCr coating were seen after long term immersing test of about 600 hours. Further, the molten alloys were easily dropped from the specimens of the MoB/CoCr coatings during the immersing test, suggesting much lower reactivity. On the other hand, an adhesion of the alloys on the coating surface of other specimens was clearly observed. This means that the MoB/CoCr coating is excellent in increasing the lifetime of mechanical parts, which come into contact with molten metal and/or alloys.

WELD OVERLAYS, more specifically chromium carbide weld overlays, have been widely used as thick coatings to protect critical plant components from abrasion wear. These thick coatings have been also considered in applications involving severe erosion, their thickness being synonymous with long life protection. Recently, boride-based arc-sprayed coatings have been developed especially for erosion control. They have demonstrated their superiority in erosion resistance over various coatings including chromium carbide submerged arc overlays. This work was undertaken to produce dense boride-based coatings comparable in thickness with carbide-based overlays. A GMAW (Gas Metal Arc Welding) welding procedure was developed for depositing boride-based overlays from cored wires. A comparative evaluation of the hardness, erosive and abrasive wear resistance of these boride-based overlays with regards to chromium and tungsten carbide overlays was carried out. Abrasion and erosion wear testing demonstrated that boride-based overlays showed higher abrasion and erosion resistance than chromium and tungsten carbide-based overlays. Overlays with higher wear resistance can be obtained if appropriate welding procedure is used to decrease weld bead dilution and therefore increase coating hardness. Results also showed that boride-based coatings deposited by arc spraying posses higher erosion resistance than those produced by the welding process.