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<p>This work successfully deposited Ni-Cr functionally graded coatings on SS304 substrates using the HVOF method, achieving a uniform thickness of 185 ± 5&#xa0;μm. Cross-sectional SEM micrographs revealed dense, crack-free morphologies, with Coating A displaying stratified lamellae and Coating B showing a compact, homogeneous structure. EBSD analysis indicated that Coating A exhibited grains in the size range of 3-9&#xa0;μm with a peak at 5-7&#xa0;μm, while Coating B demonstrated finer grains between 3 and 8&#xa0;μm, peaking closer to 6-7&#xa0;μm. Misorientation angle analysis showed Coating A contained a higher fraction of high-angle grain boundaries (&gt;15%). In contrast, Coating B exhibited dominant low-angle grain boundaries (2-10°), enhancing hardness and resistance to plastic deformation. Inverse Pole Figure (IPF) analysis revealed maximum texture intensity of 3.84 for Coating A and 4.43 for Coating B, suggesting more substantial crystallographic anisotropy in the latter. Tribological testing highlighted the distinct performance of the coatings under varying normal loads (20, 30, and 40 N). For Coating A, the coefficient of friction (COF) stabilized at 0.25 under 20 N, increased to 0.26-0.27 at 30 N, and reached 0.30-0.33 at 40 N. In contrast, Coating B consistently maintained lower COF values of 0.18, 0.21, and 0.24-0.25 under the same loads, reflecting a 15-32% reduction compared to Coating A. Wear depth analysis further showed load-dependent behavior: Coating A recorded 102.62 , 122.87 , and 139.74 microns at 20, 30, and 40 N, respectively, whereas Coating B exhibited 105.99 microns, 140.72 microns, and 167.48 microns. Friction force measurements corroborated these findings, with Coating B maintaining ~ 32% lower values at 20 N (8.31 N versus 12.29 N for Coating A).</p>

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Microstructure and Tribological Behavior of Cr-Ni Multilayer Coatings on SS304 Using High-Velocity Oxygen Fuel Process

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • MD Jamil Akhtar,
  • Ranganath M. Singari,
  • Qasim Murtaza

摘要

This work successfully deposited Ni-Cr functionally graded coatings on SS304 substrates using the HVOF method, achieving a uniform thickness of 185 ± 5 μm. Cross-sectional SEM micrographs revealed dense, crack-free morphologies, with Coating A displaying stratified lamellae and Coating B showing a compact, homogeneous structure. EBSD analysis indicated that Coating A exhibited grains in the size range of 3-9 μm with a peak at 5-7 μm, while Coating B demonstrated finer grains between 3 and 8 μm, peaking closer to 6-7 μm. Misorientation angle analysis showed Coating A contained a higher fraction of high-angle grain boundaries (>15%). In contrast, Coating B exhibited dominant low-angle grain boundaries (2-10°), enhancing hardness and resistance to plastic deformation. Inverse Pole Figure (IPF) analysis revealed maximum texture intensity of 3.84 for Coating A and 4.43 for Coating B, suggesting more substantial crystallographic anisotropy in the latter. Tribological testing highlighted the distinct performance of the coatings under varying normal loads (20, 30, and 40 N). For Coating A, the coefficient of friction (COF) stabilized at 0.25 under 20 N, increased to 0.26-0.27 at 30 N, and reached 0.30-0.33 at 40 N. In contrast, Coating B consistently maintained lower COF values of 0.18, 0.21, and 0.24-0.25 under the same loads, reflecting a 15-32% reduction compared to Coating A. Wear depth analysis further showed load-dependent behavior: Coating A recorded 102.62 , 122.87 , and 139.74 microns at 20, 30, and 40 N, respectively, whereas Coating B exhibited 105.99 microns, 140.72 microns, and 167.48 microns. Friction force measurements corroborated these findings, with Coating B maintaining ~ 32% lower values at 20 N (8.31 N versus 12.29 N for Coating A).