Search Results (7)

Thermally sprayed carbide cermet coatings, particularly those based on tungsten carbide (WC) and chromium carbide (Cr₃C₂) and produced with the high velocity oxygen fuel (HVOF) process, are used in tribological applications as environmentally friendly alternatives to electroplated hard chrome coatings. These functional coatings are especially prevalent in the automotive industry, offering excellent wear resistance. However, their mechanical and tribological performances are highly dependent on factors such as feedstock powders, spray parameters, and service conditions. This review aims to gain deeper insights into the above elements. It also outlines emerging advancements in HVOF technology—including in situ powder mixing, laser treatment, artificial intelligence integration, and the use of novel materials such as rare earth elements or transition metals—which can further enhance coating performance and broaden their applications to sectors such as the aerospace and hydro-machinery industries. Finally, this literature review focuses on process optimization and sustainability, including environmental and health impacts, critical material use, and operational limitations. It uses a life cycle assessment (LCA) as a tool for evaluating ecological performance and addresses current challenges such as exposure risks, process control constraints, and the push toward safer, more sustainable alternatives to traditional WC and Cr₃C₂ cermet coatings. Full article

The spindle is the key working part of the horizontal cotton picker, and the wear resistance of its surface directly affects the service life of the spindle. Improving the surface performance of the spindle is fundamental for improving the performance of cotton pickers. To enhance the wear resistance of the spindle surface, this study used the physical vapor deposition (PVD) technique to prepare TiN coating on the spindle substrate surface of the cotton-picking machine to improve the spindle surface rather than the original electroplated chromium coating. The microscopic morphology of the spindle was analyzed by scanning electron microscope (SEM), the mechanical and frictional properties of the spindle were tested by a nanoindentation tester and a friction wear tester, and the morphology of the worn spindle was observed by a portable microscope and a 3D surface profiler. The test results indicated that after the PVD treatment, the surface hardness of the spindle was about 2.5 times that of the electroplated chromium spindle, and the H/E value was 2.2 times that of the electroplated chromium spindle. PVD-TiN spindle showed better mechanical properties. In the friction test, under the same conditions, the wear rate of the PVD-TiN spindle was less than that of the chrome plating spindle. In a field test of 100 hm², the average wear area of the second tooth tip surface of the electroplated chromium spindle was about 2.17 times that of the PVD-TiN spindle. It was verified that the PVD-TiN spindle surface had better wear resistance than the electroplated chromium spindle. This study has certain research significance for the performance optimization of cotton pickers. Also, it is indicated that PVD-TiN coating can effectively improve the wear resistance of the spindle surface and provides a new method for enhancing the service life of the spindle. Full article

Electroplated hard chromium (EPHC) has been widely used in industry due to its excellent mechanical properties, but the development of this technology is limited by environmental risks. The physical vapor deposition (PVD) process has shown promise as an alternative to EPHC for producing chromium-based coatings. In this research, we investigate the microstructure and wear resistance of pure chromium coatings using two PVD techniques, namely, magnetron sputtering ion plating (MSIP) and micro-arc ion plating (MAIP), which are compared to EPHC. To assess wear resistance, we evaluated factors such as hardness, coating base bonding force, wear rate and friction coefficient via friction and wear experiments. The results show that, in terms of microstructure, while the EPHC coating does not exhibit a strong preferred growth orientation, the PVD coatings exhibit an obvious preferred growth orientation along the (110) direction. The average grain size of the EPHC coating is the smallest, and the PVD chromium coatings show a higher hardness than the EPHC coating. The results of pin-on-disk tests show that there is little difference in friction coefficients between EPHC and MAIP chromium plating; however, the MAIP chromium coating showed an excellent specific wear rate (as low as 1.477 × 10⁻¹³ m³/Nm). The wear condition of the MAIP chromium coating is more stable than that of the EPHC coating, indicating its potential as a replacement for EPHC. Full article

This work aims to develop a novel method for on-line monitoring of coating quality during the Extreme High-speed Laser Cladding (EHLA) process. JG-11 coating was prepared by EHLA, and microstructure, microhardness, corrosion performance, and scratch resistance were investigated. To analyze the influences of fluctuations in processing parameters on coating quality, a single-factor experiment scheme was designed and an on-line monitoring system based on laser triangulation was built. Furthermore, a new forming method for the surface profile of EHLA coating was proposed, and a new comprehensive evaluation index of surface morphology was accordingly designed. Benefitting from the extremely high cooling rate, EHLA JG-11 coating had fine grains, high hardness, and better corrosion resistance and scratch resistance than those of Electroplating Hard Chromium (EHC). The results revealed that the surface morphologies presented different characteristics due to the fluctuations of process parameters, such as high surface flatness, deep pits, small peaks, poor directionality, etc. The comprehensive evaluation index composed of S_a, S_sk, and S_tr could effectively characterize the surface morphology of EHLA coating, which proved that the monitoring system and evaluation method could realize on-line monitoring of the process parameters during the EHLA process. Full article

In view of new environmental directives, hexavalent chromium baths can no longer be used to electroplate thick hard chromium deposits. To meet these industrial and environmental challenges, deposits are developed from trivalent chromium electrolytes. Cr(III) coatings are usually studied from the point of view of the use properties and hardness, but their intrinsic properties remain widely unknown. The novelty of this work consists in the mechanical characterisation of these coatings. Properties such as hardness, stiffness, yield strength, and toughness of trivalent chromium deposits are determined by combining instrumented hardness tests, in situ FEG–SEM observations, and finite element simulations. These are explained according to the microstructure of the deposits, which is determined by scanning electron microscopy and X-ray diffraction. Their composition was characterised by glow discharge spectrometry. The structure characterisation deposits showed a more severely fractured coating of trivalent chromium than in the case of hexavalent chromium. Non-post-treated trivalent chromium deposits have a higher hardness (13 ± 1.7 GPa) and yield strength (5 GPa) than hexavalent chromium deposits. However, their stiffness (191 ± 13 GPa) and toughness (1.37 ± 0.13 MPa√m) are lower. Its mechanical behaviour is elastofragile. These differences in mechanical properties can be explained by the amorphous structure of the deposits and their high carbon content. Full article

The hydraulic support column bears loading and makes reciprocating motion ceaselessly for extended periods, so its service life is far shorter than that of the overall hydraulic support. This paper offers a comparative study on the surface coating of hydraulic support columns with hard chrome plating and high-velocity oxygen fuel (HVOF) thermal spraying refabricating to analyze the impact of different refabricating processes on the microstructure, hardness, corrosion resistance, and wear resistance of the coating (plating). The result shows that the structure of the HVOF coating is uniformly compact, and the HVOF WC10Co4Cr coating has better wear resistance, more than four times that of hard chrome plating. In the neutral salt spray test, the HVOF Ni60 coating shows rustiness at 720 h of the test, which suggests its corrosion resistance is nearly five times that of hard chrome plating. Hence, under the harsh corrosive wear environment, the refabricating HVOF Ni60 is a more suitable replacement for the hydraulic support column coating than the hard chrome plating. Thus, the HVOF Ni60 coating could be an effective replacement for hard chrome plating. Full article

The TD (Thermal Diffusion) salt bath process is used to obtain a super hard carbide coating on the material surface by utilizing the mechanism of metal thermal diffusion. In this paper, chromium carbide coating was prepared on P20 hot-pressing die steel by the TD salt bath chromizing process. Characterization of the modified surface layer was made by means of scanning electron microscopy (SEM), energy dispersive X-ray analysis (EDS), a micro-hardness tester and an automatic scratch tester. The influence rules of different salt bath times and temperatures on the growth thickness of the cladding layer were explored through experiments, and the optimum salt bath process scheme was determined as a temperature of 960 °C and time of 6 h. The chromium carbide coating with a thickness similar to that of chromium plating was prepared, and the average thickness of the coating was about 8–10 μm. The results showed that hardness and bonding strength of chromium carbide coating are higher than that of electroplated chromium coating. The combination of chromium carbide coating and matrix is metallurgical, while the electroplated chromium coating is physical. Immersion corrosion test results show that both coatings have good corrosion resistance in a 65% nitric acid solution. Full article