Study of the Tribological Properties of Self-Fluxing Nickel-Based Coatings Obtained by Gas-Flame Spraying
Abstract
1. Introduction
2. Materials and Methods
3. Results
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- The decrease in the intensity of diffraction peaks during spraying indicates that the coating obtained using the spraying method became more amorphous compared to the initial powder. This may occur due to limited cooling and rapid formation of the coating, during which large crystalline structures do not have time to form. This may also indicate the presence of micropores, which reduce the amount of crystalline phases observable in X-ray diffraction.
- -
- The increase in intensity after flame remelting compared to the sprayed layer may indicate the onset of crystallization and structural stabilization of the material. The flame remelting process leads to local heating of the coating, which promotes a more complete formation of crystalline phases. However, the intensity is still lower than that of the initial powder, indicating the presence of a considerable amount of amorphous or microcrystalline regions.
- -
- A significant increase in intensity after furnace heating indicates a more complete crystalline transformation of the material. At the high temperatures that can be reached in the furnace, the formation of a more stable and ordered crystalline structure is promoted. The increase in peak diffraction intensity at this stage may indicate crystal growth and an enhancement in lattice ordering. This is particularly noticeable with respect to the Ni peaks, which are broadened in the case of the coating. The broadening of the peaks may be associated with distortion of the crystalline structure caused by the rapid cooling of the material during the laser treatment, which is characteristic of thermally treated coatings, as demonstrated in the work of Li et al. (2001) [23].
4. Conclusions
- Phase composition (XRD): The coatings contain FeNi3 and strengthening carbides/borides (e.g., Cr7C3, Fe23(C,B)6); after heat treatment, the lattice becomes more ordered with an increase in the Ni solid-solution lattice parameter (3.55 → 3.57 Å).
- Thickness and porosity: Cross-section shows densification (thickness ~805 → 625 → 597 μm), with porosity reduced 7.866% → 3.024% → 1.767% from as-sprayed to flame-remelted to furnace-treated.
- Roughness (Ra): Surface smoothing with post-treatments: 31.860 → 14.915 → 13.388 μm (minimum after furnace treatment).
- Microhardness: Near-surface HV increases 528.7 ± 2.3 → 771.6 ± 4.6 → 922.4 ± 5.7 HV, reflecting lower porosity and a stabilized binder.
- Adhesion strength (ASTM C633): 18 → 27 → 34 MPa; the furnace treatment gives the highest coating–substrate bonding.
- Wettability (contact angle): Surface becomes less wettable as density increases: 53.152° → 79.875° → 89.603°.
- Coefficient of friction (dry, ball-on-disk): μ decreases and stabilizes with post-treatments: 0.648 ± 0.070 → 0.173 ± 0.050 → 0.138 ± 0.003; furnace treatment shows the smallest fluctuations.
- Wear-track morphology: Evolves from pronounced micro-grooves and cracking (as-sprayed) to a more uniform, “polishing-like” track with a thin tribo-film (furnace).
- Counterbody wear (100Cr6 ball): Wear-scar area shrinks with coating modification (0.889 → 0.479 → 0.0395 mm2), confirming improved tribological compatibility.
- Corrosion resistance (Tafel): Furnace treatment yields the lowest icorr/CR (e.g., CR ≈ 0.005678 mm·year−1), outperforming AISI 1045 steel and the flame-remelted state.
- Overall: Among the tested routes, furnace heat treatment at 1025 °C/5 min provides the best structure–property balance (minimum Ra and porosity, maximum HV and adhesion, low and stable μ, enhanced corrosion resistance) and is recommended to extend the service life of NiCrFeBSiC coatings under dry sliding.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
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| Steel Grade | C | Cu | Mn | As | Ni | P | S | Si | Fe |
|---|---|---|---|---|---|---|---|---|---|
| 1045 | 0.47 | 0.28 | 0.78 | 0.07 | 0.20 | 0.035 | 0.040 | 0.27 | 97.85 |
| Operation gas | Oxygen | 25 NLPM |
| Acetylene | 15 NLPM | |
| Powder carrier gas | Air | 37 NLPM |
| Spraying distance | 200 mm | |
| Spray time | 30 s | |
| Samples | Adhesion Strength, MPa | Microhardness, HV0.05 | Wettability, ° | Friction Coefficient | Roughness, μm |
|---|---|---|---|---|---|
| SF1 | 18 | 528.7 ± 2.3 | 53.152 | 0.648 ± 0.070 | 31.860 ± 0.290 |
| SF2 | 27 | 771.6 ± 4.6 | 79.875 | 0.173 ± 0.050 | 14.915 ± 0.047 |
| SF3 | 34 | 922.4 ± 5.7 | 89.603 | 0.138 ± 0.003 | 13.388 ± 0.016 |
| Sample Name | Sample Wear Rate [mm3/(N·m)] |
|---|---|
| SF1 | 0.001694 ± 0.000085 |
| SF2 | 4.102 × 10−6 ± 0.205 × 10−5 |
| SF3 | 3.458 × 10−6 ± 0.173 × 10−6 |
| Samples | Initial AISI 1045 Steel | SF1 | SF2 | SF3 |
|---|---|---|---|---|
| Icorr (A) | 0.69218 | 0.42371 | 0.39466 | 0.38963 |
| icorr (A/cm2) | 0.881757962 | 0.539757962 | 0.502751592 | 0.496343949 |
| CR (mm/a) | 0.0100873122 | 0.006174832 | 0.005751479 | 0.005678175 |
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Buitkenov, D.; Raisov, N.; Alimbekuly, T.; Alibekova, B. Study of the Tribological Properties of Self-Fluxing Nickel-Based Coatings Obtained by Gas-Flame Spraying. Crystals 2025, 15, 862. https://doi.org/10.3390/cryst15100862
Buitkenov D, Raisov N, Alimbekuly T, Alibekova B. Study of the Tribological Properties of Self-Fluxing Nickel-Based Coatings Obtained by Gas-Flame Spraying. Crystals. 2025; 15(10):862. https://doi.org/10.3390/cryst15100862
Chicago/Turabian StyleBuitkenov, Dastan, Nurmakhanbet Raisov, Temirlan Alimbekuly, and Balym Alibekova. 2025. "Study of the Tribological Properties of Self-Fluxing Nickel-Based Coatings Obtained by Gas-Flame Spraying" Crystals 15, no. 10: 862. https://doi.org/10.3390/cryst15100862
APA StyleBuitkenov, D., Raisov, N., Alimbekuly, T., & Alibekova, B. (2025). Study of the Tribological Properties of Self-Fluxing Nickel-Based Coatings Obtained by Gas-Flame Spraying. Crystals, 15(10), 862. https://doi.org/10.3390/cryst15100862

