Effect of HVOF-sprayed nanostructured WC-10Co-4Cr coating on sliding wear and tensile-tensile fatigue properties of TC6 titanium alloy

Aerospace equipment has been placing greater demands on the wear resistance and fatigue strength of titanium alloys. In light of this, the research objective was to prepare a WC-10Co-4Cr coating with better performance through the utilization of the ultra-short distance high-speed oxygen fuel (HVOF) spraying process. Then the microstructure, microhardness, sliding wear, and fatigue performance of TC6 alloy reinforced with WC-10Co-4Cr coating were further explored and analyzed. The ultra-short distance HVOF spraying process was employed to suppress decarburization, resulting in a minimal amount of W2C phase in the coating. The WC-10Co-4Cr coating exhibited excellent surface characteristics, displaying minimal microcracks and a low porosity rate of 0.15 +/- 0.08%. The interface between the coating and the substrate was sharp and clean, while the TC6 alloy retained its dual structural characteristics without any microstructural changes. The microhardness of the WC-10Co-4Cr coating exhibited a remarkable value of 1172.64 HV0.025, which is 3.2 times greater than that of the substrate. The coating exhibited a noteworthy decrease in wear rate, wear depth, and wear area, indicating superior wear resistance. Additionally, a thorough examination was conducted to uncover the underlying wear mechanism of the coating under different loads. The WC-10Co-4Cr coating, which was developed through this study, shows a minimal influence on the fatigue strength of the original base material. Furthermore, a comprehensive analysis was conducted to elucidate the factors contributing to the significant fatigue life of the WC-10Co-4Cr coating.