Thermal Spray Coating Enhancing the Wear Resistance Performance of High–Speed Components by Using Thermal Spray Coating Technique

Abstract

This research project aimed to investigate the enhancement of wear resistance in high–speed mechanical components through the application of Thermal Spray Coating technology to extend service life and improve engineering performance. The substrate material used in this study was Aluminum Alloy 6061, which is widely employed in industrial applications due to its lightweight characteristics, excellent mechanical strength, and good machinability. A Ni₉₅Al₅ alloy wire was employed as the bond coat to enhance the adhesion between the substrate and the coating layer, while WC₁₀Co₄Cr was applied as the top coat to improve surface hardness and wear resistance. The coating process consisted of depositing the bond coat using the Wire Arc Spray technique, followed by the application of the top coat using the High Velocity Oxygen Fuel (HVOF) spraying process. This combination of coating techniques is capable of producing a dense coating layer with excellent adhesion to the substrate. After the coating process, the microstructure of the coating layer was characterized using Scanning Electron Microscopy (SEM). The coating thickness was measured, and the surface hardness was evaluated to determine the mechanical properties and overall coating quality. The experimental results revealed that the Ni₉₅Al₅/WC₁₀Co₄Cr coating system significantly increased the surface hardness of the Aluminum Alloy 6061 substrate, thereby enhancing its wear resistance and making it suitable for engineering components operating under severe frictional and high–speed conditions. Furthermore, microstructural analysis demonstrated that the coating exhibited good adhesion to the substrate, a continuous coating structure throughout the sprayed area, and a relatively uniform distribution of coating particles. These findings indicate that the selected thermal spray processes are effective in producing high–quality protective coatings with considerable potential for industrial applications requiring improved surface durability and wear performance.