Microstructure and Properties of FeAlC-x(WC-Co) Composite Coating Prepared through Plasma Transfer Arc Cladding

Tungsten carbide (WC) is widely used in wear-resistant parts due to its excellent wear resistance. Iron-based alloys are used in the repair and remanufacturing of engine components due to their good compatibility with iron-based workpieces. In order to enhance the wear resistance of engine components in service under abrasive conditions, composite coatings have been prepared for cast iron engine components by adding WC-Co to iron-based powders. This study investigates the microstructure and wear properties of composite coatings of iron-based alloys reinforced with different contents of WC particles. The composite coatings mainly contained gamma-Fe, alpha-Fe, WC and Fe3W3C. With the addition of the WC-Co strengthening phase, the average hardness of the FeAlC-x(WC-Co) composite coatings increases from 524 HV0.2 to 814 HV0.2. Wear test results showed that when the WC addition was 20%, it had the lowest frictional coefficient of 0.5 and the lowest wear mass loss of 1.3 mg. Compared to the original Fe-based alloy coatings, the WC particle-reinforced FeAlC composite coatings display improved wear resistance on a reduced friction basis, mainly benefiting from the high wear resistance of the graphite solid lubrication phase and carbides in the cladding.