Next Article in Journal
Effect of Quench Tempering on Hydrogen Embrittlement and Corrosion Behavior of X100 Pipeline Steel
Next Article in Special Issue
Surface Morphology Analysis of Laser Shock Peened 20CrMnTi Steel: A Statistical Evaluation
Previous Article in Journal
Parameters Optimization of Electrical Discharge Machining Process Using Swarm Intelligence: A Review
Previous Article in Special Issue
Low-Temperature Carburization: Ex Situ Activation of Austenitic Stainless Steel
 
 
Search for Articles:
Title / Keyword
Author / Affiliation / Email
Journal
Article Type
 
 
Advanced Search
 
Section
Special Issue
Volume
Issue
Number
Page
 
Journals
Metals
Volume 13
Issue 5
10.3390/met13050840
metals-logo
Submit to this Journal Review for this Journal Propose a Special Issue
► Article Menu

Article Menu

share Share announcement Help format_quote Cite question_answer Discuss in SciProfiles thumb_up
...
Endorse textsms
...
Comment
first_page
settings
Order Article Reprints
Font Type:
Arial Georgia Verdana
Font Size:
Aa Aa Aa
Line Spacing:
Column Width:
Background:
Review

Improvement of the High Temperature Wear Resistance of Laser Cladding Nickel-Based Coating: A Review

by
Yingpeng Liu
1,
Kaiming Wang
2 and
Hanguang Fu
1,*
1
Key Laboratory of Advanced Functional Materials, Department of Materials Science and Engineering, Ministry of Education, Beijing University of Technology, Beijing 100124, China
2
College of Automobile and Mechanical Engineering, Changsha University of Science and Technology, Changsha 410114, China
*
Author to whom correspondence should be addressed.
Metals 2023, 13(5), 840; https://doi.org/10.3390/met13050840
Submission received: 23 March 2023 / Revised: 9 April 2023 / Accepted: 21 April 2023 / Published: 24 April 2023
(This article belongs to the Special Issue Surface Engineering and Coating Tribology)
Browse Figures
Versions Notes

Abstract

:
Nickel-based coatings obtained by laser melting are broadly applied for surface modification owing to their high bond strength and exceptional wear resistance. Nickel-based laser cladding coatings are also extensively employed in high temperature wear environments. In this paper, the research progress on improving the high temperature wear resistance of laser cladding nickel-based composite coatings was reviewed by introducing a hard ceramic phase, adding solid lubricants and rare earth elements. On this basis, the material system to enhance the high temperature wear resistance of coating was summarized from the perspectives of the type, addition amount, morphology and distribution law of the hard ceramic phase, etc. The synergistic effect of various lubricants on improving the high temperature wear resistance of coating was discussed, and the action mechanism of solid lubricants in the high temperature extreme environment was analyzed. Finally, this paper summarizes the main difficulties involved in increasing the high temperature wear resistance of nickel-based coatings and some problems worthy of attention in the future development.

1. Introduction

Some instruments and equipment in aerospace, vehicles and ships, petrochemical and other fields have a harsh working environment. For example, turbine engine rotors for large engines, gas turbine blades, bearings, etc., need to be served in high temperature environments for a long time [1,2,3,4]. Wear of components poses a risk to the safe use of the equipment and also increases the production costs of companies. Therefore, promoting the abrasion resistance of materials in high temperature environments is an important challenge in the field of tribology [5,6]. In comparison with the conventional surface modification process, laser cladding exhibits the benefit of higher energy density and lower dilution rate, which enables effective refinement of the tissue and improvement of coating elemental segregation [7,8,9]. Nickel-based powder has favorable corrosion resistance and wettability, and the Cr elements in the melt pool will react with C and B elements to produce Cr7C3, Cr23C6, CrB and other phases during the preparation of the coating by laser cladding, which are capable of raising the microhardness and wear resistance of the coating [10,11]. However, as the temperature increases, the phase within the NiCrBSi coating starts to change. The γ-Ni grains within the coating grow gradually when the temperature increases to 480 °C. In accordance with Hall–Petch equation, it is well known that the hardness of the coating decreases as the grain size increases, which eventually leads to a decrease in the abrasion resistance of the coating [12,13]. At 600 °C, the hard ceramic phase Cr7C3, which has a high content in the NiCrBSi coating, starts to coarsen and the hardness of the coating decreases [14]. CrB precipitation can be observed in the γ-Ni substrate at 700 °C, and this reduces the solid solution strengthening effect of Cr in the substrate. The interplate polymerization force and toughness of the coating decrease, and the abrasion resistance of the coating deteriorates [15].
At present, domestic and foreign scholars have conducted a lot of research and explored a series of alloy systems around enhancing the wear resistance of Nickel-based composite coatings at room temperature [16,17,18]. However, few have collated the results of promoting the high temperature wear resistance of laser-cladding Nickel-based coatings. A review of the relevant literature reveals that the improvement of high temperature wear resistance of Nickel-based coatings is mainly through the addition of hard ceramic phases and lubricants. The addition of a hard ceramic phase is principally to maintain the high hardness of the coating under high temperature conditions and to avoid the coating from spalling in a large area during the abrasion process so that the coating has good high temperature wear resistance. Adding lubricants is another common method. The lower the coefficient of friction of a material, the better its wear resistance. The solid lubricant still has superior lubrication at high temperatures and raises the high temperature abrasion resistance of the coating by decreasing the friction coefficient of the coating.

2. Ceramic Phase

The wear resistance of a material is usually positively correlated with the hardness of the material, and the addition of hard ceramic phases to Nickel-based coatings can effectively boost the microhardness of the coating and thus, its wear resistance [19,20]. At room temperature, the wear resistance of coatings is usually improved by adding hard ceramic phases such as Cr3C2, B4C, TiC, WC, and NbC [21,22,23,24,25]. However, due to the decomposition and transformation of most hard ceramic phases under high temperature conditions, the number and stability of hard ceramic phases in the coating decreases, resulting in a significant reduction in the wear resistance of the coating. After years of research and exploration, the current additive phases with better effects on improving the high temperature wear resistance of nickel-based coatings are WC and TaC.

2.1. WC

WC has a high melting point of 2600 °C and is stable at high temperatures. Table 1 summarizes the material systems, high temperature wear resistance test conditions and the key findings for the accession of WC to improve the high temperature wear resistance of laser cladding Ni-based coatings.
Professor Zhou’s group at the Chinese Academy of Sciences investigated the influence of WC under the high temperature abrasion resistance of nickel-based coatings [26]. When comparing the abrasion of Nickel based coating and NiCrBSi/WC nickel-based composite coating at 500 °C during testing, it was found that the wear rate of the coating decreased significantly after the addition of WC. Experimentally, it is demonstrated that the addition of WC is effective in improving the high temperature abrasion resistance of nickel-based coatings. Notably, the COF (Coefficient of friction) of NiCrBSi/WC Nickel-based composite coating is higher and fluctuates significantly at each temperature. The authors suggest that this may be attributed to the non-uniform distribution of the hard ceramic phase of WC in the composite coating. The larger WC phase is dislodged to become abrasive particles during the frictional wear experiments and severe three-body wear occurs between the coating and the Si3N4 grinding balls, thus causing an increase in the COF. This phenomenon has also been observed in many papers [27,28,29]. In order to expand the applicability of titanium and titanium alloys, Guo et al. [30] prepared NiCrBSi and NiCrBSi/WC-Ni composite coatings over pure titanium plates to research the impact of WC on the high temperature abrasion resistance in Ni-based coatings. The results of frictional wear tests at 300 °C and 500 °C demonstrated that both kinds of coatings experienced slight abrasive and fatigue wear. In addition, due to the high hardness of WC, the abrasion ratio of Ni-based composite coating with WC addition is approximately 24–47 times higher than that of pure titanium matrix. The influence of various amounts of CeO2 additives on the high temperature wear resistance of NiCrBSi/WC coatings was studied further by Wang et al. [31]. NiCrBSi/WC coating wear mechanism under high temperature is adhesive wear and oxidation wear, while the additive of rare earth oxide changes the wear mechanism. Furthermore, 0.5% CeO2 had the most obvious improvement in the wear resistance, at which time the wear mechanism of the coating surface was slightly abrasive wear.
Table
Table 1. Test and key findings of adding WC to improve wear resistance of coating at high temperature.
Table 1. Test and key findings of adding WC to improve wear resistance of coating at high temperature.
Ref.SubstrateMatrixCeramic PhaseKey FindingsTribological Testing
Process, Parameters
Zhou, 2011 [26]1Cr18Ni 9TiNiCrBSiWCCoatings produced by supplementing WC powder with NiCrBSi display greater high temperature abrasion resistance than NiCrBSi coatingsA THT07-135 pin-on-disk tribometer; Si3N4 ball (diameter 6 mm); Load: 5 N; Temperature: 25, 500 °C; Sliding speed 300 mm/s; Sliding distance: 500 m
Guo, 2010 [30]pure Ti discsNiCrBSiWCUnder similar circumstances, the abrasion rate of the NiCrBSi/WC-Ni composite coating is around 24–47 times lower than that of the pure Ti substrateA THT07-135 pin-on-disk tribometer; Si3N4 ball (6 mm). Temperatures: 300 °C, 500 °C; Load: 5 N; Sliding speed: 300 mm/s; Sliding distance: 500 m
Wang, 2013 [31]4Cr14Ni14NW2MoNiCrBSiWC, CeO2Ni21 + 20%WC + 0.5%CeO2 coating microstructure was effectively refined and the coating presented a relatively well-abrasive behaviorA MG-200 high speed and temperature wear test machine. Grinding ring: heat-resistant cast iron; Temperature: RT (Rome temperature), 250, 450 and 650 °C; Load: 300 N;
Velocity: 25 r/s; Load time: 3~3.5 min

2.2. TaC

As a robust carbide-forming element under high temperatures, Ta is an attractive additive for enhancing the high temperature wear resistance of coatings as it is very easy to form thermally stable TaC with C in the melt pool [32,33,34]. Table 2 is a summary of the investigations for the inclusion of TaC to improve the high temperature wear resistance of laser cladding Ni-based coatings.
Lv et al. [35] prepared NiCrBSi/TaC composite coatings on Ti6Al4V surfaces by the mechanical addition method, and 5 wt.% addition of TaC was sufficient to significantly reduce the amount of wear of the coatings at 600 °C. This is due to the dissolution of TaC in the melt pool, which is the initial precipitation as the core of non-uniform nucleation when the melt pool was cooled, accelerating the nucleation efficiency and refining the microstructure. In addition, the solid solution of Ta in the melt pool into TiNi, Ti2Ni and other intermetallic compounds further enhances the strength of the coating and effectively enhances the high temperature abrasive resistance. Yu et al. [36] mechanically mixed different percentages of Ta powder (0 wt.% to 10 wt.%) with Ni-based powder on the surface of medium carbon steel to study the improvement of the wear resistance of nickel-based coatings by the addition of Ta. As shown in the TEM analysis of Figure 1, Ta combines with C to form a high hardness. Stable bulk TaC phase under the high temperature action of the melt pool, and it is observed under the high-resolution TEM that Ta does not form amorphous phases after reacting with the elements, and the TaC/substrate interface is well bonded. In addition, the oxide layer which develops in the wear surfacing acts as a lubricant during the abrasion process, decreasing the COF during testing and boosting the high temperature wear resistance. Yu et al. [37] prepared NiAlCrTaC composite coatings under the surface of Inconel 625 Ni-based high-temperature alloy and found that the addition of TaC boost the wear resistance of the coatings obviously at 25 °C, 300 °C, 550 °C and 700 °C. At 550 °C, the oxide in the oxide layer of the NiAlCr coating grows dramatically, which results in under-sintering and extensive spalling of the oxide layer, and the COF and Wear weightlessness are noticeably increased. The Ta element in the coating inhibits the growth of Al2O3 oxide and promotes the sintering of the oxide layer, thus forming a continuous dense oxide layer on the abrasive surface and reducing the wear loss. At 700 °C, the TaC grains in the NiAlCrTaC composite coating withstand the burden and prevent micro-cutting of debris, thus forming an oxide layer from damage and providing the coating with good wear resistance under high temperature conditions.

2.3. Other Ceramic Phase

Table 3 concludes the status of the incorporation of the other ceramic phase to promote the high temperature wear resistance of laser cladding Ni-based coatings.
Zan et al. [38] tried to add a metal-ceramic composite powder NiCr-Cr3C2 to Ni45 powder to enhance the high temperature wear resistance of nickel-based coatings, and the abrasive of the coating decreased compared to the matrix. However, the wear loss increased with temperature and the wear resistance was essentially the same as that of the matrix under high temperature conditions. This is due to the stability of Cr3C2 decreasing above 600 °C, which makes it difficult to support the wear as a hard ceramic phase. This limits the application of Cr3C2 to enhance the high temperature abrasive resistance. ZrB2 has a melting point as high as 3040 °C and high strength at both room and high temperatures, and as a typical ultra-high temperature ceramic is an ideal additive to promote the high temperature wear resistance of nickel-based coatings [39]. Guo et al. [40] researched ZrB2 on the high temperature wear resistance of nickel-based coatings and found that the added ZrB2 acts as a hard ceramic phase to support and protect the substrate during the wear process, making only slight abrasion marks on the wear surface.
Table
Table 3. Test and key findings of adding hard ceramic phase to improve wear resistance of coating at high temperature.
Table 3. Test and key findings of adding hard ceramic phase to improve wear resistance of coating at high temperature.
Ref.SubstrateMatrixCeramic PhaseKey FindingsTribological Testing Process, Parameters
Zang, 2015 [38]20Cr2Ni4ANi45NiCr-Cr3C2NiCr–Cr3C2 coating has a better abrasive rate and lower COF A ball-on-plate friction test; Temperatures: 20, 100 and 300 °C using; SiC ball (d = 10 mm); Load: 3 kg; The stroke: 1000 μm; frequency: 50 Hz Time: 30 min
Guo, 2013 [40]pure Ti discsNiCoCrAlY alloy powderZrB2The addition of ZrB2 as a hard ceramic phase to support and protect the substrate during the wear process, resulting in only slight wear marks on the surface in the friction testA SRV-IV friction and wear tester. Si3N4 balls (d = 1 cm); Temperature: 20, 100, 300 and 500 °C; Load: 40 N; frequency: 15 Hz; Time: 15 min
Sun, 2022 [41]Q235 low carbon steelNi60AACu, CuMo, CuMoWThe additive of Cu refines the organization of the coating and results in the formation of NiCu solid solution. Resists wear and lubricationMMQ-02G; The zirconia ball
(4 mm); Temperature: RT, 600 °C; Time: 30 min; Load: 30 N; Frequency: 1 Hz
Sun et al. [41] made the first study on the results of Cu, Mo and W to boost the wear resistance of nickel-based coatings by adding W to the powder of Ni60AACuMo composition to prepare the coatings and to investigate their microstructure and wear resistance. The study results demonstrated that WC was generated after the addition of W, and the microhardness of the coating was slightly boosted. While, the preferential precipitation of the WC phase consumed the C element in the γ phase and inhibited the carbide precipitation, the wear resistance decreased.
In summary, the authors concluded that the appropriate addition of hard ceramic phases during coating preparation or in situ ceramic phases in the coating by adding an appropriate amount of elements, is an attractive way of achieving greater high temperature wear resistance of laser cladding nickel-based composite coatings. However, compared with room temperature conditions, the types of hard ceramic phases added to enhance the wear resistance of coatings at high temperature are relatively single, and the current research is mainly focused on WC and TaC. Both TiC and NbC have melting points above 3000 °C and the hardness is also higher, and many studies have indicated that the in situ synthesized NiCrBSi/TiC and NiCrBSi/NbC coatings have good interfacial bonding. Researchers are expected to explore further.

3. Solid Lubricants

Lubricants can be classified as solid, semi-solid and liquid lubricants according to their morphology, but only solid lubricants can meet the wear resistance requirements of materials under high temperature [42]. Researchers have tried to add various solid lubricants to nickel-based alloys for more than a decade since the beginning of the 21st century, and nickel-based self-lubricating alloy systems have been explored [43]. Solid lubricants could be classified into three categories according to the lubrication mechanism: one is lamellar solid lubricants (MoS2, graphite, Hexagonal boron nitride(h-BN), and others, with the crystal structure shown in Figure 2 [44,45]) due to the weak interplanar cohesive bonds and strong anisotropy between lamellar solid surfaces and the lamellar structure functions as a self-lubricating agent under low shear stress conditions [46]. Another common solid lubricant is soft metal, as shown in Figure 3, which mainly relies on the metal’s own low shear strength and strong ductility to form a thin friction layer on the relatively hard contact surface [47]. In addition, as shown in Figure 4, a few chemically stable oxides and fluorides are also employed as high temperature solid lubricants [48]. However, fluorides have not been investigated to enhance the high temperature abrasive resistance.

3.1. Lamellar Solids

MoS2 and graphite have a laminate structure where shearing can easily occur, which can provide self-lubricating properties to the coating, and are common lubricants under normal temperature conditions. However, oxidation occurs above 350 °C for MoS2 and above 450 °C for graphite. When the temperature increases, such lubricants gradually oxidize to induce degradation of their structure and their lubrication effect is greatly reduced, so few attempts have been made to add MoS2 and graphite alone to boost the high temperature wear resistance [49].
Although the vast majority of consequences indicate that sulfides have little effect on wear resistance enhancement above 300 °C, researchers have not stopped studying sulfides to boost the wear resistance of nickel-based coatings. The study of adding solid lubricants such as sulfide and Mo to improve the high temperature wear resistance of laser-fused nickel-based coatings is summarized in Table 4.
The team of Prof. H. Torres [50] studied the wear behavior of coatings incorporating MoS2 and WS2 at different temperatures. As shown in Figure 5, the addition of Cu and Ag further enhanced the wear resistance at room temperature, however, under high temperature requirements, the friction coefficient increases significantly and the surface wear resistance at high temperature of the coating is somewhat worse than that of NiCrBSi coating. This is primarily attributed to the dissolution and oxidation of sulfides at high temperatures and the formation of more debris on the surface of the coating during the friction test. The effect of three sulfides, Ni3S2, CuS, and Bi2S3, on the wear resistance of Ni-based coatings was first investigated by the team of Prof. R. Kumar [51] at temperatures of 400 and 600 °C. The coatings with the three components maintained a high hardness at high temperatures. Along with the increase in temperature from 25 °C to 600 °C, the microhardness decreased by about 20%. As shown in Figure 5, the COF of the three coatings with sulfide addition at 400 °C was reduced and more uniform and stable, and the self-lubricating behavior reduced the amount of wear by 40%. However, as the temperature rose to 600 °C, the COF of the three sulfide-added coatings began to fluctuate sharply and the amount of wear increased greatly. This indicates that it is difficult for Ni3S2, CuS and Bi2S3 to make an effective improvement in the abrasive resistance of Ni-based coatings at 600 °C. Sulfides are unstable and easily oxidized at high temperatures, particularly above 610 °C when the COF of the coating raises sharply, and are not effective in improving the high temperature wear resistance of nickel-based coatings [52]. The authors concluded that the encapsulation on the surface of sulfide by chemical plating proposed by Liu [53] can effectively inhibit its decomposition but also can boost the compatibility with the substrate.
Dilawary et al. [54] incorporated an Mo element to Ni-based coatings and the oxide layer was formed by oxidation of debris at the coating surface during wear at 700 °C. MoO2, an oxide of Mo, increased the hardness while acting as a solid lubricant to reduce the wear coefficient of the coating. Sun et al. [41] prepared Ni60AACuMo composite coatings by adding Mo again on top of the added Cu powder, but the frictional wear results at 600 °C showed that the wear resistance of the coatings decreased. This is principally a result of the serious decrease in hardness of the Ni60AACuMo coating after the addition of Mo, which led to the hard ceramic phase flaking off from the substrate under the load during the frictional wear process, and the formation of abrasive particles aggravated the wear of the coating during the subsequent frictional wear test.
Ti3SiC2 has a hexagonal lamellar structure and is a potential solid lubricant with self-lubricating properties [55]. Liu et al. [56] added 5, 10, and 15 wt.% of Ti3SiC2 to Ni45 powder to promote the high temperature wear resistance of the coating. The wear of the coating was significantly reduced by the synergistic effect of the coating oxide film and Ti3SiC2, but the experimental analysis revealed that different additions had different strengthening mechanisms on the microhardness of the coating. When a small amount of Ti3SiC2 was added, it mainly acted as a heterogeneous nucleation core to promote grain refinement, while when the added amount was higher, Ti3SiC2 enhanced the hardness of the coating by causing lattice distortion and diffusion strengthening.
Table
Table 4. Tests and crucial findings on the addition of solid lubricants to enhance the high temperature wear resistance of coatings.
Table 4. Tests and crucial findings on the addition of solid lubricants to enhance the high temperature wear resistance of coatings.
Ref.SubstrateMatrixCeramic PhaseKey FindingsTribological Testing Process,
Parameters
Torres, 2018 [50]stainless steelNiCrBSiMoS2, WS2, Ag, CuThe high temperature wear resistance of the coating decreases after the addition of Cu and AgAISI 52,100 bearing balls with a diameter of 10 mm; Load: 50 N. Temperature: RT, 150, 300, 400, 600 °C; Wear time: 900 s; Stroke length: 2 mm
Kumar, 2023 [51]stainless steelNiCrBSiNi3S2, CuS, Bi2S3The coating retains high hardness at high temperatures, but the friction coefficients all become unstableBall-on-plate configuration; Load: 50 N; Frequency and stroke: 25 Hz and 0.2 cm; Sliding speeds of 10 cm/s. Time: 900 s; Temperature: 25, 400, 600 °C
Dilawary, 2018 [54]AISI 4140 steelNiCrBSiMoMoO2 can not only enhance the hardness but also act as a solid lubricant to decrease the wear coefficient of the coating
A ball-on-disc configuration; Load: 3 N; Contact pressure: 1.0 GPa; Temperatures: RT, 300, 500 and 700 °C
Sun, 2022 [41]Q235Ni60AACu, CuMo, CuMoWMainly due to the fine and uniform microstructure and the formation of NiCu solid solution phase, the coating with the addition of Cu exhibits excellent wear resistance MMQ-02G; The zirconia ball with a radius of 4 mm; Temperature: RT, 600 °C; Time: 30 min; Load: 30 N; Frequency: 1 Hz
Liu, 2021 [56]304 stainless steelNi60Ti3SiC2Ti3SiC2 synergizes with Ni60 oxide film for better lubrication performance at high temperaturesSi3N4 ball (diameter: 5 mm); Load: 5 N; Time: 30 min; The rotation velocity is 560 r/min. Temperature: 25, 600 °C
H-BN is an isomer of boron nitride, known as “white graphite” due to its hexagonal dot matrix crystal structure similar to graphite and its good lubricity [57]. Its crystal structure determines that its shear properties are anisotropic, preferentially shearing in the direction parallel to the base or perpendicular to the c-axis when subjected to shear forces [58,59]. In addition, h-BN has strong oxidation resistance and high thermal stability, so it is widely applied to promote high temperature wear resistance of nickel-based coatings. Studies on h-BN to ameliorate the high temperature wear resistance of coatings are summarized in Table 5.
Zhang et al. [60] prepared Ni60 + h-BN coatings on Ti-6Al-4V surface, and XPS, SEM, and EDS analyses demonstrated that most of h-BN decomposed under the action of laser and undergone in situ reaction in the melt pool to synthesize TiB, TiN and TiO phases to boost the hardness and wear resistance of the coatings. The TiN phase boosts the hardness and wear resistance of the coating, and the NiO, TiO2, Al2O3 and other metal oxides in the coating act as lubrication and wear reduction under the high temperature environment, and the synergistic effect makes the coating obtain good wear resistance even under the high temperature condition. Lu et al. [61] produced Ni60 + h-BN coating over Ti-6Al-4V surface, and the dry sliding wear test conditions resulted in the best wear resistance of the Ni-10 wt.% h-BN composition at 25, 300, and 600 °C. The wear morphology of the coating surface for each group at 600 °C is shown in Figure 6. The wear mechanisms are minimal abrasive wear and brittle fracture as well as the breakdown of the transfer layer. This is primarily caused by the fact that most of h-BN decomposes to produce TiB2 to promote the hardness of the coating, and the residual h-BN forms a lubricating film on the friction surface to ensure the abrasive resistance of the coating under high temperature conditions. Zhang et al. [62] produced Ni/h-BN coating on the surface of 1Cr18Ni9Ti, and the high temperature wear resistance of the coating was promoted compared to other groupings at the same temperature. The wear resistance of the coating increased instead with the increase of temperature in the range of 0–600 °C, and its wear resistance decreased in the range of 600–800 °C due to the decrease of hardness of the coating. Liu et al. [63] produced nickel-based coatings by adding WS2 + h-BN with self-lubricating properties and hard ceramic phase TiN to Ni60, and the experimental results indicated that the average microhardness of the coating was 1.3 to 1.7 times higher than that of the substrate, the COF of the coating was stable around 0.3458, and the wear resistance of the coating was significantly improved.
C-BN has an outstanding hardness, thermal stability and wear resistance; h-BN has exceptional thermal stability, chemical inertness and lubricity; and c-BN can be transformed into h-BN at 1540 °C [64,65,66]. Zhao et al. [67] investigated the effect of h-BN (A1) and c-BN (A2) on the properties of two boron nitride isomers in the range of 25–800 °C, based on the effect of Ni60 + MoO3 composite coatings on the structure and properties. Wrapping a copper layer around the interface of c-BN particles can both decrease the laser absorption of c-BN and prevent the conversion of all c-BN particles to h-BN, and react with MoO3 to form CuMoO4 solid lubricant. XRD analysis showed that under the high temperature of the laser cladding melt pool, some of the c-BN changed to h-BN, while the other part reacted with the elements in Ni60 powder to form Cr(Mo)B, Cr5B3, CrN and MoN enhancers. The test outcomes indicate that the composite coatings containing c-BN have higher hardness and wear resistance from 25 °C to 800 °C with different degrees of improvement, and the wear rate is reduced by 77%, 61%, 29%, 46% and 39%, respectively. This is due to the increased hardness of the composite coating by the retained c-BN. A study by Yang et al. [68] showed that the mismatch rate of the lattice constant between the matrix and the reinforced phase is an important factor affecting the strength of the interfacial bond. The lower the mismatch rate, the stronger the interfacial bond. The mismatch rate of Cr(Mo)B and γ-(Ni, M) matrices was computed by the following equation [69]. Combined with the TEM image in Figure 7, the interatomic distance was measured. The calculated results show that   δ A 1 = 63.0 % and δ A 2 = 5.15 % , indicating that the interfacial bonding strength between the reinforcing phase and the substrate in the A2 coating was higher. The hardness and interfacial bonding strength of the coating with the addition of c-BN were increased, in addition, the high temperature wear resistance of the coating was significantly enhanced compared to that for h-BN.
δ = a α − a β a α + a β 2
Table
Table 5. Test and key discovery of adding solid lubricant to improve wear resistance of coating at high temperature.
Table 5. Test and key discovery of adding solid lubricant to improve wear resistance of coating at high temperature.
Ref.SubstrateMatrixCeramic PhaseKey FindingsTribological Testing Process,
Parameters
Zhang, 2019 [60]Ti6Al4VNi60h-BNThe h-BN particles were decomposed to synthesize TiB and TiN in situ in the melt pool to resist wear. The metal oxides produced at high temperatures act as a lubricantA ball-on-disk type friction and wear test machine; Si3N4 ceramic balls of Φ 6 mm; Rate: 5 Hz; Load: 5 N; Duration: 60 min
Lu, 2016 [61]Ti6Al4VNiCrBSih-BNMost of the h-BN decompose to produce TiB2, which boosts the hardness of the coating. The residual h-BN acts as a lubricant during frictionA ball-on-disk tribo-meter; Temperature: 20, 300, 600 °C; The counter-body was a Si3N4 ceramic ball (d = 4 mm); Duration: 30 min
Zhang, 2008 [62]1Cr18Ni9TiNickel powderh-BNAt lower temperatures, coating wear resistance increases with increasing temperature; in the range of 600–800 °C, coating wear resistance decreases due to the decrease in hardness.A GWY-2000 ball-on-disc friction and wear tester; Si3N4 ceramic
(d = 10); Load: 100 N; Sliding speed: 0.226 m/s; Duration: 20 min
Liu, 2020 [63]TC4Ni60TiN, WS2 + h-BNThe addition of WS2 + h-BN and TiN increased the average microhardness of the coating by 1.3–1.7 times, and the friction coefficient of the coating was stableA pin-and-disc friction and wear tester. Duration: 30 min; Load: 50 N, the speed was 100 rpm, the grinding radius: 3 mm. WC ball (d = 9.5 mm)
Zhao, 2021 [67]Q235Ni60Cu/h-BN + MoO3The breakdown of c-BN boosts the bond strength between Cr(Mo)B and the substrate. At the same time, h-BN provides a low coefficient of friction over a broad range of temperaturesA dry sliding pin-on-disk device. Al2O3 balls (d = 5 mm); load: 3 kg; rotating speed: 50 rpm; The rotation diameter 0.1 cm; friction duration: and 0.5 h
Liu, 2022 [70]45# steelNi60CuCu plays the friction transfer film and oxidation double-layer self-lubrication. Ni60-5 wt.%Cu composition of the coating, the coefficient of friction at 600 °C is 0.267High temperature tribometer with Si3N4 ceramic balls on disk using Φ 6 mm; load: 5 N; time: 30 min; temperature: RT, 600 °C.

3.2. Soft Metals

Cu has a face-centered cubic crystal structure with an atomic radius similar to that of Ni and can combine with Ni atoms to form (Ni, Cu) solid solutions under high temperature conditions [71]; Mo oxides can enhance the microstructure and properties of the coatings [72]. Liu et al. [70] added different levels of Cu to Ni60 powder to study the effect of Cu amount on the tissue evolvement and tribological behavior in laser-fused Ni60 composite coatings. Since Cu acts as a friction transmission membrane and an oxide double layer self-lubrication, the coatings with Cu exhibit good wear resistance, especially the coatings with Ni60-5 wt.%Cu composition, the friction coefficient at 600 °C is only 0.267. Coatings were prepared by adding Cu, CuMo and CuMoW to Ni60AA and their wear resistance was evaluated at 25 and 600 °C, respectively. The Ni60AACu coatings were found to have the best wear resistance [41]. This is mainly due to the fact that the microstructure of the coating becomes uniform and fine after the addition of Cu, and Cu replaces part of Ni to form NiCu solid solution, which acts as a lubricant in the frictional wear process and reduces the wear of the coating [70]. The hardness of the Ni60AACuMo coating decreases severely after the addition of Mo, resulting in the hard ceramic phase flaking off from the substrate under the action of external forces during the friction process. The formation of abrasive particles aggravates the wear of the coating during the subsequent friction wear test. Since soft metals soften at higher temperatures and their wear resistance decreases significantly in service environments above 500 °C, more existing studies have prepared coatings by adding soft metals together with other hard ceramic phases or lubricants [73,74]. The synergistic action of two or more lubricants can stabilize the high temperature wear resistance of the coatings at a high level, such as constituting Ag/MoS2/G [75], Ag/WS2/h-BN [76], Cu/c-BN/MoO3 [71], Cu/MoS2 [50], Cu/WS2 [77], Mo2N/MoS2/Ag [78], and Ag/MoS2 [79] alloy systems.

4. Conclusions

In the aerospace, automotive and petrochemical industries, some parts are used in high temperature environments for long periods. Improvement of the high temperature wear resistance of the material is essential to extend the service life of the equipment and diminish equipment wear. This paper reviews the current status of research on improving the high temperature wear resistance of laser-cladding nickel-based coatings and draws the following conclusions:
(1)
The wear resistance of the coating is highly correlated with the hardness. The addition of a hard ceramic phase can make the coating maintain a relatively high hardness under the high temperature condition and thus boost the high temperature wear resistance of the coating. Compared with a wide variety of added phases at room temperature, the hard ceramic phase added to enhance high temperature wear resistance is relatively single. The improvement effect of a large number of hard ceramic phases on high temperature wear resistance is yet to be explored. Future work could revolve around a wider range of hard ceramic phases to improve the high temperature wear resistance of coatings. At the same time, the synergistic effect of various hard phases can be studied. In addition, the effects of an electric field, magnetic field, vibration and other auxiliary treatments on high temperature wear resistance of nickel-based coatings can be systematically studied.
(2)
The interplanar cohesive bonds between the lamellar solid surfaces are weak, and the lamellar structure plays a self-lubricating role under low shear stress conditions. Soft metal’s own low shear strength and strong ductility in the relatively hard contact surface form a thin layer of soft friction layer. These two types of solid lubricants in high temperature conditions can play a useful role in improving the wear resistance of nickel-based coatings.
(3)
The existing lubricant takes effect in a narrow range, and the wear resistance of the coating decreases remarkably after exceeding the applicable temperature range. Future solutions: one is to develop new high temperature lubricating materials with better lubrication effect and wider temperature ranges. The other is through the synergistic effect of multiple lubricants, the high temperature wear resistance of the coating can be maintained at a high level.

Author Contributions

Literature research, manuscript writing and data collection: Y.L.; Supervision and data analysis: K.W.; First draft revision, project management and manuscript writing: H.F. All authors have read and agreed to the published version of the manuscript.

Funding

This research was funded by R&D Program of Beijing Municipal Education Commission (Grant number KZ202210005004) and the National Natural Science Foundation of China (Grant number 52205334).

Data Availability Statement

All data is contained within the article.

Conflicts of Interest

The authors declare no conflict of interest.

References

  1. Calleja, A.; Fernández, A.; Rodríguez, A.; Lacalle, L.N.L.; Lamikiz, A. Turn-milling of blades in turning centres and multitasking machines controlling tool tilt angle. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 2015, 229, 1324–1336. [Google Scholar] [CrossRef]
  2. Ortiz, M.; Penalva, M.; Iriondo, E.; Lacalle, L. Investigation of Thermal-Related Effects in Hot SPIF of Ti-6Al-4V Alloy. Int. J. Precis. Eng. Manuf.-Green Technol. 2020, 7, 299–317. [Google Scholar] [CrossRef]
  3. Barrio, H.; Ochoa, A.; Lacalle, L.; Lamikiz, A. Hybrid manufacturing of complex components: Full methodology including laser metal deposition (LMD) module development, cladding geometry estimation and case study validation. Mech. Syst. Signal Process. 2022, 179, 109337. [Google Scholar] [CrossRef]
  4. Xue, J.L.; Guo, W.; Yang, J.; Xia, M.S.; Zhao, G.; Tan, C.W.; Wan, Z.D.; Chi, J.X.; Zhang, H.Q. In-situ observation of microcrack initiation and damage nucleation modes on the HAZ of laser-welded DP1180 joint. J. Mater. Sci. Technol. 2023, 148, 138–149. [Google Scholar] [CrossRef]
  5. Zhao, W.; Zha, G.C.; Kong, F.X.; Wu, M.L.; Feng, X.; Gao, S.Y. Strengthening Effect of Incremental Shear Deformation on Ti Alloy Clad Plate with a Ni-Based Alloy Laser-Clad Layer. J. Mater. Eng. Perform. 2017, 26, 2411–2416. [Google Scholar] [CrossRef]
  6. Feng, K.; Chen, Y.; Deng, P.S.; Li, Y.Y.; Zhao, H.X.; Lu, F.G.; Li, R.F.; Huang, J.; Li, Z.G. Improved high-temperature hardness and wear resistance of Inconel 625 coatings fabricated by laser cladding. J. Mater. Process. Technol. 2017, 243, 82–91. [Google Scholar] [CrossRef]
  7. Calleja, A.; Tabernero, I.; Ealo, J.A.; Campa, F.J.; Lamikiz, A.; Lacalle, L. Feed rate calculation algorithm for the homogeneous material deposition of blisk blades by 5-axis laser cladding. Int. J. Adv. Manuf. Technol. 2014, 74, 1219–1228. [Google Scholar] [CrossRef]
  8. Zhang, L.; Wang, C.; Qian, S.; Yu, Q.; Dong, C. Microstructure and Wear Resistance of Laser-Clad (Co, Ni)61.2B26.2Si7.8Ta4.8 Coatings. Metals 2017, 7, 419. [Google Scholar] [CrossRef]
  9. Han, T.F.; Zhou, K.; Chen, Z.; Gao, Y. Research Progress on Laser Cladding Alloying and Composite Processing of Steel Materials. Metals 2022, 12, 2055. [Google Scholar] [CrossRef]
  10. Zeng, J.Y.; Lian, G.F.; Chen, C.R.; Huang, X. Influences of the TiC composite introduction method on the microstructures and properties of Nickel-Based coatings. Opt. Laser Technol. 2022, 156, 108633. [Google Scholar] [CrossRef]
  11. Wang, K.M.; Liu, W.; Hong, Y.X.; Shakhawat, S.H.M.; Tong, Y.G.; Hu, Y.L.; Zhang, M.J.; Zhang, J.; Xiang, D.D.; Fu, H.G.; et al. An Overview of Technological Parameter Optimization in the Case of Laser Cladding. Coatings 2023, 13, 496. [Google Scholar] [CrossRef]
  12. Chen, L.Y.; Xu, T.X.; Lu, S.; Wang, Z.X.; Chen, S.J.; Zhang, L.C. Improved hardness and wear resistance of plasma sprayed nanostructured NiCrBSi coating via short-time heat treatment. Surf. Coat. Technol. 2018, 350, 436–444. [Google Scholar] [CrossRef]
  13. Pérez-Ruiz, J.D.; Lacalle, L.; Urbikain, G.; Pereira, O.; Martínez, S.; Bris, J. On the relationship between cutting forces and anisotropy features in the milling of LPBF Inconel 718 for near net shape parts. Int. J. Mach. Tools Manuf. 2021, 170, 103801. [Google Scholar] [CrossRef]
  14. Liu, L.; Qiao, Y.; Xu, P. Effect of La2O3 on Microstructure and Properties of Laser Cladding SMA Coating on AISI 304 Stainless Steel. Coatings 2022, 12, 1004. [Google Scholar] [CrossRef]
  15. Liu, L.; Xu, H.; Xiao, J.; Wei, X.; Zhang, G.; Zhang, C. Effect of heat treatment on structure and property evolutions of atmospheric plasma sprayed NiCrBSi coatings. Surf. Coat. Technol. 2017, 325, 548–554. [Google Scholar] [CrossRef]
  16. Chen, L.Y.; Wang, H.Y.; Zhao, C.H.; Lu, S.; Wang, Z.X.; Sha, J.; Chen, S.J.; Zhang, L.C. Automatic remelting and enhanced mechanical performance of a plasma sprayed NiCrBSi coating. Surf. Coat. Technol. 2019, 369, 31–43. [Google Scholar] [CrossRef]
  17. Fereiduni, E.; Ghasemi, A.; Elbestawi, M. Unique opportunities for microstructure engineering via trace B4C addition to Ti-6Al-4V through laser powder bed fusion process: As-built and heat-treated scenarios. Addit. Manuf. 2022, 50, 102557. [Google Scholar] [CrossRef]
  18. Meng, Q.W.; Geng, L.; Zhang, B.Y. Laser cladding of Ni-base composite coatings onto Ti-6Al-4V substrates with pre-placed B4C+NiCrBSi powders. Surf. Coat. Technol. 2006, 200, 4923–4928. [Google Scholar] [CrossRef]
  19. Wang, K.M.; Chang, B.H.; Chen, J.S.; Fu, H.G.; Lin, Y.H.; Lei, Y.P. Effect of Molybdenum on the Microstructures and Properties of Stainless Steel Coatings by Laser Cladding. Appl. Sci. 2017, 7, 1065. [Google Scholar] [CrossRef]
  20. Di, R.F.; Zhang, J.Q.; Qian, Z.; Fang, Y.; Tian, H.F.; Song, H.Y.; Lei, J.B. Effect of WC-12Co on the mechanical and wear performance of laser melting deposition nickel-based alloy. Opt. Laser Technol. 2022, 152, 108094. [Google Scholar] [CrossRef]
  21. Chen, L.Y.; Yu, T.B.; Chen, X.; Zhao, Y.; Guan, C. Process optimization, microstructure and microhardness of coaxial laser cladding TiC reinforced Ni-based composite coatings. Opt. Laser Technol. 2022, 152, 108129. [Google Scholar] [CrossRef]
  22. Li, Y.T.; Fu, H.G.; Ma, T.J.; Wang, K.M.; Yang, X.J.; Lin, J. Microstructure and wear resistance of AlCoCrFeNi-WC/TiC composite coating by laser cladding. Mater. Charact. 2022, 194, 112479. [Google Scholar] [CrossRef]
  23. Zhao, Y.; Yu, T.B.; Sun, J.Y. Microstructure and properties of laser cladded B4C/TiC/Ni-based composite coating. Int. J. Refract. Met. Hard Mater. 2020, 86, 105112. [Google Scholar] [CrossRef]
  24. Liu, Y.P.; Liang, Y.L.; Fu, H.G. Improvement properties of laser cladding Ni45-Cr3C2 coatings by adding B4C and V. Mater. Sci. Technol. 2022, 39, 443–453. [Google Scholar]
  25. Li, X.; Feng, Y.; Liu, B.; Yi, D.; Yang, X.; Zhang, W.; Chen, G.; Liu, Y.; Bai, P. Influence of NbC particles on microstructure and mechanical properties of AlCoCrFeNi high-entropy alloy coatings prepared by laser cladding. J. Alloys Compd. 2019, 788, 485–494. [Google Scholar] [CrossRef]
  26. Guo, C.; Zhou, J.S.; Chen, J.M.; Zhao, J.R.; Yu, Y.J.; Zhou, H.D. High temperature wear resistance of laser cladding NiCrBSi and NiCrBSi/WC-Ni composite coatings. Wear 2011, 270, 492–498. [Google Scholar] [CrossRef]
  27. Hong, S.; Ma, Q.; Liu, G.; Yang, H.; Hu, L.; Meng, W.; Xie, H.; Yin, X. In-situ reinforced phase evolution and wear resistance of nickel-based composite coatings fabricated by wide-band laser cladding with Nb addition. Opt. Laser Technol. 2023, 157, 108678. [Google Scholar] [CrossRef]
  28. Zhang, P.; Pang, Y.; Yu, M. Effects of WC Particle Types on the Microstructures and Properties of WC-Reinforced Ni60 Composite Coatings Produced by Laser Cladding. Metals 2019, 9, 583. [Google Scholar] [CrossRef]
  29. Bartkowski, D.; Mlynarczak, A.; Piasecki, A.; Dudziak, B.; Goscianski, M.; Bartkowska, A. Microstructure, microhardness and corrosion resistance of Stellite-6 coatings reinforced with WC particles using laser cladding. Opt. Laser. Technol. 2015, 68, 191–201. [Google Scholar] [CrossRef]
  30. Guo, C.; Zhou, J.S.; Chen, J.S.; Zhao, J.R.; Yu, Y.J.; Zhou, H.D. Improvement of the oxidation and wear resistance of pure Ti by laser cladding at elevated temperature. Surf. Coat. Technol. 2010, 205, 2142–2151. [Google Scholar] [CrossRef]
  31. Wang, X.H.; Liu, A.M. Microstructure and Abrasive-wear Behavior Under High Temperature of Laser Clad Ni-based WC Ceramic Coating. Phys. Procedia 2013, 50, 145–149. [Google Scholar] [CrossRef]
  32. Li, Z.; Yan, H.; Zhang, P.; Guo, J.; Yu, Z.; Ringsberg, J.W. Improving surface resistance to wear and corrosion of nickel-aluminum bronze by laser-clad TaC/Co-based alloy composite coatings. Surf. Coat. Technol. 2021, 405, 126592. [Google Scholar] [CrossRef]
  33. Nieto, A.; Kumar, A.; Lahiri, D.; Zhang, C.; Seal, S.; Agarwal, A. Oxidation behavior of graphene nanoplatelet reinforced tantalum carbide composites in high temperature plasma flow. Carbon 2014, 67, 398–408. [Google Scholar] [CrossRef]
  34. Smith, C.J.; Ross, M.A.; De Leon, N.; Weinberger, C.R.; Thompson, G.B. Ultra-high temperature deformation in TaC and HfC. J. Eur. Ceram. Soc. 2018, 38, 5319–5332. [Google Scholar] [CrossRef]
  35. Lv, Y.H.; Li, J.; Tao, Y.F.; Hu, L.F. High-temperature wear and oxidation behaviors of TiNi/Ti2Ni matrix composite coatings with TaC addition prepared on Ti6Al4V by laser cladding. Appl. Surf. Sci. 2017, 402, 478–494. [Google Scholar] [CrossRef]
  36. Yu, T.; Chen, J.; Wen, Y.M.; Deng, Q.L. High temperature phase stability and wear behavior of laser clad Ta reinforced NiCrBSi coating. Appl. Surf. Sci. 2021, 547, 149171. [Google Scholar] [CrossRef]
  37. Yu, T.; Tang, H. Microstructure and high-temperature wear behavior of laser clad TaC-reinforced Ni-Al-Cr coating. Appl. Surf. Sci. 2022, 592, 153263. [Google Scholar] [CrossRef]
  38. Zang, C.C.; Wang, Y.Z.; Zhang, Y.D.; Li, J.H.; Zeng, H.; Zhang, D.Q. Microstructure and wear-resistant properties of NiCr-Cr3C2 coating with Ni45 transition layer produced by laser cladding. Rare Met. 2015, 34, 491–497. [Google Scholar] [CrossRef]
  39. Farotade, G.A.; Adesina, O.S.; Popoola, A.P.I.; Pityana, S.L. Laser Cladding and Characterization of Ni–SiC–ZrB2 Cermet Coatings on Ti–6Al–4V for High-Temperature Applications. Metallogr. Microstruct. Anal. 2019, 8, 349–358. [Google Scholar] [CrossRef]
  40. Guo, C.; Chen, J.M.; Yao, R.G.; Zhou, J.S. Microstructure and High Temperature Wear Resistance of Laser Cladding NiCoCrAlY/ZrB2 Coating. Rare Met. Mater. Eng. 2013, 42, 1547–1551. [Google Scholar]
  41. Sun, Y.; Gao, J.; Wang, K.N.; Song, Q.; Cui, H.Z.; Li, W.S.; Wang, C.M. The effect of multi-element alloying on the structure and properties of laser cladding nickel-based coatings. Surf. Coat. Technol. 2023, 454, 129174. [Google Scholar]
  42. Sarkar, M.; Mandal, N. Solid lubricant materials for high temperature application: A review. Mater. Today Proc. 2022, 66, 3762–3768. [Google Scholar] [CrossRef]
  43. Akhtar, S.S. A critical review on self-lubricating ceramic-composite cutting tools. Ceram. Int. 2021, 47, 20745–20767. [Google Scholar] [CrossRef]
  44. Torres, H.; Ripoll, M.R.; Prakash, B. Tribological behaviour of self-lubricating materials at high temperatures. Int. Mater. Rev. 2018, 63, 309–340. [Google Scholar] [CrossRef]
  45. Kumar, R.; Hussainova, I.; Rahmani, R.; Antonov, M. Solid Lubrication at High-Temperatures—A Review. Materials. 2022, 15, 1695. [Google Scholar] [CrossRef]
  46. Pawlak, Z.; Kaldonski, T.J.; Macko, M.; Urbaniak, W. h-BN lamellar lubricant in hydrocarbon and formulated oil in porous sintered bearings (iron+h-BN). Arch. Civ. Mech. Eng. 2017, 17, 687–693. [Google Scholar] [CrossRef]
  47. Zhu, S.Y.; Cheng, J.; Qiao, Z.H.; Yang, J. High temperature solid-lubricating materials: A review. Tribol. Int. 2019, 133, 206–223. [Google Scholar] [CrossRef]
  48. Kumar, R.; Antonov, M.; Liu, L.; Hussainova, I. Sliding wear performance of in-situ spark plasma sintered Ti-TiBw composite at temperatures up to 900 °C. Wear 2021, 476, 203663. [Google Scholar] [CrossRef]
  49. Valefi, M.; de Rooij, M.; Schipper, D.J.; Winnubst, L. Effect of temperature on friction and wear behaviour of CuO–zirconia composites. J. Eur. Ceram. Soc. 2012, 32, 2235–2242. [Google Scholar] [CrossRef]
  50. Torres, H.; Vuchkov, T.; Slawik, S.; Gachot, C.; Prakash, B.; Rodríguez Ripoll, M. Self-lubricating laser claddings for reducing friction and wear from room temperature to 600 °C. Wear 2018, 408–409, 22–33. [Google Scholar] [CrossRef]
  51. Kumar, R.; Torres, H.; Aydinyan, S.; Antonov, M.; Varga, M.; Hussainova, I.; Rodriguez Ripoll, M. Tribological behavior of Ni-based self-lubricating claddings containing sulfide of nickel, copper, or bismuth at temperatures up to 600 °C. Surf. Coat. Technol. 2023, 456, 129270. [Google Scholar] [CrossRef]
  52. Torres, H.; Caykara, T.; Hardell, J.; Nurminen, J.; Prakash, B.; Rodríguez Ripoll, M. Tribological performance of iron- and nickel-base self-lubricating claddings containing metal sulfides at high temperature. Friction 2022, 10, 2069–2085. [Google Scholar] [CrossRef]
  53. Liu, X.B.; Zheng, C.; Liu, Y.F.; Fan, J.W.; Yang, M.S.; He, X.M.; Wang, M.D.; Yang, H.B.; Qi, L.H. A comparative study of laser cladding high temperature wear-resistant composite coating with the addition of self-lubricating WS2 and WS2/(Ni–P) encapsulation. J. Mater. Process. Technol. 2013, 213, 51–58. [Google Scholar] [CrossRef]
  54. Dilawary, S.A.A.; Motallebzadeh, A.; Atar, E.; Cimenoglu, H. Influence of Mo on the high temperature wear performance of NiCrBSi hardfacings. Tribol. Int. 2018, 127, 288–295. [Google Scholar] [CrossRef]
  55. Yan, H.; Liu, K.; Zhang, P.; Zhao, J.; Qin, Y.; Lu, Q.; Yu, Z. Fabrication and tribological behaviors of Ti3SiC2/Ti5Si3/TiC/Ni-based composite coatings by laser cladding for self-lubricating applications. Opt. Laser Technol. 2020, 126, 106077. [Google Scholar] [CrossRef]
  56. Liu, Y.F.; Zhuang, S.G.; Liu, X.B.; OuYang, C.S.; Zhu, Y.; Meng, Y. Microstructure evolution and high-temperature tribological behavior of Ti3SiC2 reinforced Ni60 composite coatings on 304 stainless steel by laser cladding. Surf. Coat. Technol. 2021, 420, 127335. [Google Scholar] [CrossRef]
  57. Xu, Y.H.; Ji, Z.X.; Yang, Z.Y.; Yang, J.S.; Li, R.; Fu, Z.D.; Liao, N.; Li, Y.W. Densification and comprehensive properties of h-BN-based refractories with in-situ formation of Y3Al5O12. J. Alloys Compd. 2021, 875, 160018. [Google Scholar] [CrossRef]
  58. Chen, J.J.; Sun, Q.C.; Chen, W.Y.; Zhu, S.Y.; Li, W.S.; Cheng, J.; Yang, J. High-temperature tribological behaviors of ZrO2/h-BN/SiC composite under air and vacuum environments. Tribol. Int. 2021, 154, 106748. [Google Scholar] [CrossRef]
  59. Corthay, S.; Kutzhanov, M.K.; Narzulloev, U.U.; Konopatsky, A.S.; Matveev, A.T.; Shtansky, D.V. Ni/h-BN composites with high strength and ductility. Mater. Lett. 2022, 308, 131285. [Google Scholar] [CrossRef]
  60. Zhang, D.; Cui, X.F.; Jin, G.; Song, Q.L.; Yuan, C.F.; Fang, Y.C.; Wen, X. Microstructure and Tribological Performance of Laser-Cladded Ni60+h-BN Coatings on Ti-6Al-4V Alloy at High Temperature. Tribol. Trans. 2019, 62, 779–788. [Google Scholar] [CrossRef]
  61. Lu, X.L.; Liu, X.B.; Yu, P.C.; Qiao, S.J.; Zhai, Y.J.; Wang, M.D.; Chen, Y.; Xu, D. Synthesis and characterization of Ni60-hBN high temperature self-lubricating anti-wear composite coatings on Ti6Al4V alloy by laser cladding. Opt. Laser Technol. 2016, 78, 87–94. [Google Scholar] [CrossRef]
  62. Zhang, S.T.; Zhou, J.S.; Guo, B.G.; Zhou, H.D.; Pu, Y.P.; Chen, J.M. Friction and wear behavior of laser cladding Ni/hBN self-lubricating composite coating. Mater. Sci. Eng. A 2008, 491, 47–54. [Google Scholar]
  63. Liu, K.; Yan, H.; Zhang, P.; Zhao, J.; Yu, Z.; Lu, Q. Wear Behaviors of TiN/WS2 + hBN/NiCrBSi Self-Lubricating Composite Coatings on TC4 Alloy by Laser Cladding. Coatings 2020, 10, 747. [Google Scholar] [CrossRef]
  64. Luo, X.T.; Li, C.J. Large sized cubic BN reinforced nanocomposite with improved abrasive wear resistance deposited by cold spray. Mater. Des. 2015, 83, 249–256. [Google Scholar] [CrossRef]
  65. Pawlak, Z.; Kaldonski, T.; Pai, R.; Bayraktar, E.; Oloyede, A. A comparative study on the tribological behavior of hexagonal boron nitride (h-BN) as lubricating micro-particles-an additive in porous sliding bearing for a car clutch. Wear 2009, 267, 1198–1202. [Google Scholar] [CrossRef]
  66. Li, X.; Gao, Y.; Wei, S.; Yang, Q. Tribological behavior of B4C-hBN ceramic composites used as pins or discs coupled with B4C ceramic under dry sliding condition. Ceram. Int. 2017, 43, 1578–1583. [Google Scholar] [CrossRef]
  67. Zhao, Y.; Li, R.F.; Wu, M.F.; Yue, H.Y.; Li, T.T.; Chen, Y. Effect of c-BN on the microstructure and high temperature wear resistance of laser cladded Ni-based composite coating. Surf. Coat. Technol. 2021, 421, 127466. [Google Scholar] [CrossRef]
  68. Zhou, Y.; Lian, J.; Wang, J.J. Molecular dynamics simulation of thin film interfacial strength dependency on lattice mismatch. Thin Solid Film. 2013, 537, 190–197. [Google Scholar]
  69. Wang, K.M.; Fu, H.G.; Lei, Y.P. A study of laser cladding NiCrBSi/Mo composite coatings. Surf. Eng. 2018, 34, 267–275. [Google Scholar]
  70. Liu, Q.S.; Liu, X.B.; Wang, G.; Liu, Y.F.; Meng, Y.; Zhang, S.H. Effect of Cu content on microstructure evolution and tribological behaviors of Ni60 composite coatings on 45# steel by laser cladding. Opt. Laser Technol. 2022, 156, 108549. [Google Scholar]
  71. Kong, L.Q.; Bi, Q.L.; Zhu, S.Y.; Qiao, Z.H.; Yang, J.; Liu, W.M. Effect of CuO on self-lubricating properties of ZrO2(Y2O3)–Mo composites at high temperatures. J. Eur. Ceram. Soc. 2014, 34, 1289–1296. [Google Scholar] [CrossRef]
  72. Torres, H.; Rojacz, H.; Coga, L.; Kalin, M.; Ripoll, M.R. Local mechanical and frictional properties of Ag/MoS2-doped self-lubricating Ni-based laser claddings and resulting high temperature vacuum performance. Mater. Des. 2020, 186, 108296. [Google Scholar] [CrossRef]
  73. Zhao, Y.; Feng, K.; Yao, C.W.; Nie, P.L.; Huang, J.; Li, Z.G. Microstructure and tribological properties of laser cladded self-lubricating nickel-base composite coatings containing nano-Cu and h-BN solid lubricants. Surf. Coat. Technol. 2019, 359, 485–494. [Google Scholar] [CrossRef]
  74. Ouyang, J.H.; Li, Y.F.; Zhang, Y.Z.; Wang, Y.M.; Wang, Y.J. High-Temperature Solid Lubricants and Self-Lubricating Composites: A Critical Review. Lubricants 2022, 10, 177. [Google Scholar] [CrossRef]
  75. Chen, F.; Feng, Y.; Shao, H.; Zhang, X.; Chen, J.; Chen, N. Friction and Wear Behaviors of Ag/MoS2/G Composite in Different Atmospheres and at Different Temperatures. Tribol. Lett. 2012, 47, 139–148. [Google Scholar] [CrossRef]
  76. Shi, X.; Song, S.; Zhai, W.; Wang, M.; Xu, Z.; Yao, J.; Qamar ud Din, A.; Zhang, Q. Tribological behavior of Ni3Al matrix self-lubricating composites containing WS2, Ag and hBN tested from room temperature to 800 °C. Mater. Des. 2014, 55, 75–84. [Google Scholar] [CrossRef]
  77. Yuan, J.H.; Yao, Y.G.; Zhuang, M.X.; Du, Y.Y.; Wang, L.; Yu, Z.S. Effects of Cu and WS2 addition on microstructural evolution and tribological properties of self-lubricating anti-wear coatings prepared by laser cladding. Tribol. Int. 2021, 157, 106872. [Google Scholar] [CrossRef]
  78. Aouadi, S.M.; Paudel, Y.; Luster, B.; Stadler, S.; Kohli, P.; Muratore, C.; Hager, C.; Voevodin, A.A. Adaptive Mo2N/MoS2/Ag Tribological Nanocomposite Coatings for Aerospace Applications. Tribol. Lett. 2008, 29, 95–103. [Google Scholar] [CrossRef]
  79. Chen, J.; An, Y.; Yang, J.; Zhao, X.; Yan, F.; Zhou, H.; Chen, J. Tribological properties of adaptive NiCrAlY-Ag-Mo coatings prepared by atmospheric plasma spraying. Surf. Coat. Technol. 2013, 235, 521–528. [Google Scholar] [CrossRef]
Metals 13 00840 g001 550
Figure 1. TEM photographs of Ta-containing coatings: (a) morphology; (b) SAED of TaC; (c) SAED of chromium borides; (d) HRTEM of chromium boride; (e) high magnified view labeled in (a); (f) HRTEM of the interface between TaC and chromium boride, reprinted with permission from Ref. [36], Copyright 2021 Elsevier.
Figure 1. TEM photographs of Ta-containing coatings: (a) morphology; (b) SAED of TaC; (c) SAED of chromium borides; (d) HRTEM of chromium boride; (e) high magnified view labeled in (a); (f) HRTEM of the interface between TaC and chromium boride, reprinted with permission from Ref. [36], Copyright 2021 Elsevier.
Metals 13 00840 g001
Metals 13 00840 g002 550
Figure 2. Crystal structure of several typical lamellar solid lubricants: (a) MoS2 (or WS2); (b) A single graphene layer and graphite as a stack of multiple graphene layers; (c) h-BN, reprinted with permission from Ref. [44], Copyright 2018 Taylor & Francis and reprinted from Ref. [45].
Figure 2. Crystal structure of several typical lamellar solid lubricants: (a) MoS2 (or WS2); (b) A single graphene layer and graphite as a stack of multiple graphene layers; (c) h-BN, reprinted with permission from Ref. [44], Copyright 2018 Taylor & Francis and reprinted from Ref. [45].
Metals 13 00840 g002
Metals 13 00840 g003 550
Figure 3. Diffusion mechanism of solid lubrication on soft metal matrix, reprinted from Ref. [45].
Figure 3. Diffusion mechanism of solid lubrication on soft metal matrix, reprinted from Ref. [45].
Metals 13 00840 g003
Metals 13 00840 g004 550
Figure 4. A mechanism to reduce wear at high temperatures by forming a uniform friction layer (composed of TiO2 and boric acid), reprinted from Ref. [45] and reprinted with permission from Ref. [48], Copyright 2021 Elsevier.
Figure 4. A mechanism to reduce wear at high temperatures by forming a uniform friction layer (composed of TiO2 and boric acid), reprinted from Ref. [45] and reprinted with permission from Ref. [48], Copyright 2021 Elsevier.
Metals 13 00840 g004
Metals 13 00840 g005 550
Figure 5. The results of sulfide on the friction coefficient and wear rate of coating: (a) Wear coefficient, reprinted with permission from Ref. [50], Copyright 2018 Elsevier; (b) Wear rate, reprinted with permission from Ref. [51], Copyright 2023 Elsevier.
Figure 5. The results of sulfide on the friction coefficient and wear rate of coating: (a) Wear coefficient, reprinted with permission from Ref. [50], Copyright 2018 Elsevier; (b) Wear rate, reprinted with permission from Ref. [51], Copyright 2023 Elsevier.
Metals 13 00840 g005
Metals 13 00840 g006 550
Figure 6. SEM micrographs of the surface wear morphology of the coatings at 600 °C: (a) substrate; (b) Ni60 coating; (c) Ni60 coating with 5% h-BN addition; (d) Ni60 coating with 10% h-BN addition reprinted with permission from Ref. [61], Copyright 2016 Elsevier.
Figure 6. SEM micrographs of the surface wear morphology of the coatings at 600 °C: (a) substrate; (b) Ni60 coating; (c) Ni60 coating with 5% h-BN addition; (d) Ni60 coating with 10% h-BN addition reprinted with permission from Ref. [61], Copyright 2016 Elsevier.
Metals 13 00840 g006
Metals 13 00840 g007 550
Figure 7. Results of TEM analysis. (a1,c1): bright field phase of A1; (a2,c2): bright field image of A2; (b1,d1): HRTEM and FFT results of selected region of A1; (b2,d2): HRTEM and FFT results of selected region of A2, reprinted with permission from Ref. [67], Copyright 2021 Elsevier.
Figure 7. Results of TEM analysis. (a1,c1): bright field phase of A1; (a2,c2): bright field image of A2; (b1,d1): HRTEM and FFT results of selected region of A1; (b2,d2): HRTEM and FFT results of selected region of A2, reprinted with permission from Ref. [67], Copyright 2021 Elsevier.
Metals 13 00840 g007
Table
Table 2. Test and key findings of adding TaC to improve wear resistance of coating at high temperature.
Table 2. Test and key findings of adding TaC to improve wear resistance of coating at high temperature.
Ref.SubstrateMatrixCeramic PhaseKey FindingsTribological Testing Process, Parameters
Li, 2017 [35]Ti6Al4VNiCrBSiTaCThe addition of TaC obviously refines the microstructure of the coating; the hardness and high temperature wear resistance of the coating are improvedA GHT-1000E high-temperature tribometer; Hard Si3N4 ceramic balls (d = 4 mm); Load: 10 N; Temperature: 600 °C; Tliding speed: 0.188 m/s
Yu, 2021 [36]Medium carbon steelNiCrBSiTaTaC synthesized in situ has higher hardness and thermal stability, stronger bonding at TaC/substrate intersectionA pin-on-disc tribometer; Al2O3 disk; Load: 90 N; Temperature: 25, 300 °C, 600 and 700 °C; Sliding speed: 790 m m/s; Time: 60 min
Yu, 2022 [37]Inconel 625 Nickel-based alloyNi-Al-CrTa, C powderTaC grains withstand the burden and prevent micro-cutting of debris. Ta inhibits the growth of Al2O3 and accelerates the sintering of the oxide layer, forming a dense oxide layer over the wear surfaceA pin-on-disc tribometer; Load: 60 N; Temperatures: RT, 300 °C, 550 °C and 700 °C; Time: 1 h; Sliding speed: 0.105 m/s
Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to people or property resulting from any ideas, methods, instructions or products referred to in the content.

Share and Cite

MDPI and ACS Style

Liu, Y.; Wang, K.; Fu, H. Improvement of the High Temperature Wear Resistance of Laser Cladding Nickel-Based Coating: A Review. Metals 2023, 13, 840. https://doi.org/10.3390/met13050840

AMA Style

Liu Y, Wang K, Fu H. Improvement of the High Temperature Wear Resistance of Laser Cladding Nickel-Based Coating: A Review. Metals. 2023; 13(5):840. https://doi.org/10.3390/met13050840

Chicago/Turabian Style

Liu, Yingpeng, Kaiming Wang, and Hanguang Fu. 2023. "Improvement of the High Temperature Wear Resistance of Laser Cladding Nickel-Based Coating: A Review" Metals 13, no. 5: 840. https://doi.org/10.3390/met13050840

Note that from the first issue of 2016, this journal uses article numbers instead of page numbers. See further details here.

Article Metrics

Back to TopTop