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Microstructure and Mechanical–Tribological Properties of HVOF-Sprayed (WC-Co+Ni) Coatings on Ductile Cast Iron.

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Title: Microstructure and Mechanical–Tribological Properties of HVOF-Sprayed (WC-Co+Ni) Coatings on Ductile Cast Iron.
Authors: Ksiazek, Marzanna1 (AUTHOR) mksiazek@agh.edu.pl, Boron, Lukasz2 (AUTHOR), Tchorz, Adam1,2 (AUTHOR)
Source: Materials (1996-1944). Jun2026, Vol. 19 Issue 12, p2640. 21p.
Subjects: Tungsten carbide-cobalt alloys, Microstructure, Wear resistance, Nodular iron, Surface interactions, Mechanical behavior of materials, Metal spraying
Abstract: High Velocity Oxy-Fuel (HVOF) thermal spraying enables the deposition of dense coatings with low porosity, high hardness, and good fracture resistance. Tungsten carbide–cobalt (WC-Co) coatings are widely used in industrial and aerospace applications due to their excellent wear resistance; however, improving crack resistance and coating–substrate adhesion remains a key challenge. In this study, WC-Co+Ni composite coatings were deposited on ductile cast iron, with emphasis on the role of Ni addition in controlling microstructure development under HVOF conditions. Microstructural characterization was performed using optical, scanning, and transmission electron microscopy (OM, SEM, TEM), while phase composition and chemical analysis were determined by X-ray diffraction (XRD) and energy-dispersive spectroscopy (EDS). The coatings exhibited a dense, low-porosity microstructure composed of fine WC and W2C carbides embedded in a Co–Ni binder, with locally nanocrystalline regions. XRD analysis confirmed WC and W2C as the dominant phases, with weak reflections corresponding to the η-phase (Co6W6C), indicating local decarburization. The addition of Ni increases the fraction of the transient liquid phase during particle flight, enhancing carbide dissolution and mass transport in the binder, which accelerates decarburization kinetics and promotes η-phase formation. Simultaneously, Ni modifies the binder into a more ductile Co–Ni matrix, reducing the detrimental effect of brittle η-phase on coating integrity. Mechanical and tribological testing (instrumented indentation and scratch testing) demonstrated improved crack resistance, wear resistance, and adhesion. The results show that Ni addition enables process-driven microstructural tailoring of HVOF-sprayed WC-Co coatings, leading to enhanced performance despite the presence of η-phase. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Microstructure and Mechanical–Tribological Properties of HVOF-Sprayed (WC-Co+Ni) Coatings on Ductile Cast Iron.
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Jun2026, Vol. 19 Issue 12, p2640. 21p.
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  Data: <searchLink fieldCode="DE" term="%22Tungsten+carbide-cobalt+alloys%22">Tungsten carbide-cobalt alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Microstructure%22">Microstructure</searchLink><br /><searchLink fieldCode="DE" term="%22Wear+resistance%22">Wear resistance</searchLink><br /><searchLink fieldCode="DE" term="%22Nodular+iron%22">Nodular iron</searchLink><br /><searchLink fieldCode="DE" term="%22Surface+interactions%22">Surface interactions</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Metal+spraying%22">Metal spraying</searchLink>
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  Label: Abstract
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  Data: High Velocity Oxy-Fuel (HVOF) thermal spraying enables the deposition of dense coatings with low porosity, high hardness, and good fracture resistance. Tungsten carbide–cobalt (WC-Co) coatings are widely used in industrial and aerospace applications due to their excellent wear resistance; however, improving crack resistance and coating–substrate adhesion remains a key challenge. In this study, WC-Co+Ni composite coatings were deposited on ductile cast iron, with emphasis on the role of Ni addition in controlling microstructure development under HVOF conditions. Microstructural characterization was performed using optical, scanning, and transmission electron microscopy (OM, SEM, TEM), while phase composition and chemical analysis were determined by X-ray diffraction (XRD) and energy-dispersive spectroscopy (EDS). The coatings exhibited a dense, low-porosity microstructure composed of fine WC and W2C carbides embedded in a Co–Ni binder, with locally nanocrystalline regions. XRD analysis confirmed WC and W2C as the dominant phases, with weak reflections corresponding to the η-phase (Co6W6C), indicating local decarburization. The addition of Ni increases the fraction of the transient liquid phase during particle flight, enhancing carbide dissolution and mass transport in the binder, which accelerates decarburization kinetics and promotes η-phase formation. Simultaneously, Ni modifies the binder into a more ductile Co–Ni matrix, reducing the detrimental effect of brittle η-phase on coating integrity. Mechanical and tribological testing (instrumented indentation and scratch testing) demonstrated improved crack resistance, wear resistance, and adhesion. The results show that Ni addition enables process-driven microstructural tailoring of HVOF-sprayed WC-Co coatings, leading to enhanced performance despite the presence of η-phase. [ABSTRACT FROM AUTHOR]
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  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19122640
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      – Code: eng
        Text: English
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        PageCount: 21
        StartPage: 2640
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      – SubjectFull: Tungsten carbide-cobalt alloys
        Type: general
      – SubjectFull: Microstructure
        Type: general
      – SubjectFull: Wear resistance
        Type: general
      – SubjectFull: Nodular iron
        Type: general
      – SubjectFull: Surface interactions
        Type: general
      – SubjectFull: Mechanical behavior of materials
        Type: general
      – SubjectFull: Metal spraying
        Type: general
    Titles:
      – TitleFull: Microstructure and Mechanical–Tribological Properties of HVOF-Sprayed (WC-Co+Ni) Coatings on Ductile Cast Iron.
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            NameFull: Ksiazek, Marzanna
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            NameFull: Boron, Lukasz
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            – D: 15
              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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