Sprayed deposits using conventional wire and powder materials open a wide range of possibilities to solve wear problems in engineering equipment. The option for new different spray technologies and consumables like nanostructured powder materials and nanocomposite cored wires has expanded the engineering possibilities. Cored wire technology allows the use of compositions that cannot be drawn into wire form like carbides in metallic matrix and high-temperature materials, thus intensifying the use of low operating cost welding and spraying processes to demanding wear applications. The objective of this work was to compare the mechanical characteristics and erosive wear performance of coatings obtained by Flame Spray and High Velocity Oxygen Fuel Spray using some selected powder and flexi-cord wire materials. The wear resistance of the coatings was determinate by slurry erosion wear test.

The main objective of this study is to compare the wear resistance of coatings obtained by gas metal arc (GMA) welding, wire arc spraying, and high-velocity oxyfuel (HVOF) spraying. Tungsten and chromium carbide (WC-Co and CrC-NiCr), iron alloy (Vecalloy B and 140-MXC), and 420 stainless steel coatings were deposited on low carbon steel substrates by the appropriate method. The coatings were examined by optical and scanning electron microscopy, showing no signs of spallation nor relevant level of defects. WC-Co coatings obtained by HVOF spraying exhibited the best abrasive wear resistance. Nanostructured Fe-alloy coatings applied by wire arc spraying performed almost 50% better than HVOF sprayed CrC and only 15% worse than WC-17Co. The erosion resistance of the two WC-Co coatings was very close, although WC-12Co was slightly better possibly due to its higher microhardness, lower porosity, and higher residual compressive stresses.