Journal of Applied Science and Engineering, Vol. 20, No. 4, pp. 445-452 (2017) DOI: 10.6180/jase.2017.20.4.

05

Role of Thermal Spray Coatings on Wear, Erosion

and Corrosion Behavior: A Review
Jimmy Mehta, Varinder Kumar Mittal and Pallav Gupta*
Department of Mechanical Engineering, A.S.E.T., Amity University,
Uttar Pradesh, Noida-201313, India

Abstract
Wear, erosion and corrosion are the common problems been faced by every industry. Thermal
spray coatings have emerged as one of the best technique to provide excellent resistance to wear and
erosion. These spray techniques lead to superior bond strength, low porosity, resistance to erosion-
corrosion, etc. Different compositions of CrC-NiCr, WC-Co, AlO-TiO, etc. are extensively used in a
wide variety of applications like gas turbines, boilers, shovel blades, aircrafts, etc. to improve the
abrasive wear. Much literature is available for detonation gun, high velocity oxy-fuel and plasma spray
as coating techniques. In recent years, efforts have been made to use alloy substrates and rare earth
metals with different composition for developing new coatings. In this review paper, comprehensive
and critical analysis has been made on available literature for different types of spray coatings and their
applications.

Key Words: Thermal Spray Coatings (TSC), Detonation Gun, High Velocity Oxy-fuel, Wear,
Erosion, Corrosion

1. Introduction spray coating techniques, detonation spray and HVOF

spray are the best choices to get hard, dense and wear re-
Tribology is derived from a Greek word “Tribos” sistant coatings [1]. Diverse functions of the protective
means rubbing. It deals with friction, wear and lubrication coatings can be listed such as wear and corrosion resis-
in all contacting parts. Mechanical components have been tance, thermal or electrical insulation, etc. that can be
used in variety of applications to serve under severe con- achieved through different available coating techniques
ditions of high load, high/low temperature and adverse and coating materials [2]. There are various thermal spray
chemical environment. However, wear is very common coating techniques available and selection of the best
problems, which have been faced in almost all industries technique depends upon the functional requirements,
wherever mechanical/moving components are involved. adaptability to the coating material for the intended tech-
As a result, these components are required to be replaced nique including level of adhesion (size, shape, and metal-
or repaired immediately else it would increase the cost and lurgy of the substrate), availability and cost of the equip-
decrease the service life of the component, thus affecting ment [3]. Types of thermal spray techniques are: Plasma
the efficiency of operation. Surface coatings are widely spray, Detonation Gun spray, Wire arc spraying, Flame
used which can act as a barrier between the bare metal and spray, High velocity oxy-fuel coating (HVOF), Warm
the catastrophic environmental conditions thereby en- spraying and Cold spraying [4]. Figure 1 shows the basic
hancing the service life of the component/assembly. Table steps of thermal spray process. The various types of coat-
1 shows the difference between various types of coating ing which are being used include:
methods. Among the commercially available thermal 1. Metallic: NiCrAlY, Cr3C2-NiCr, Tribo-alloy etc.
2. Carbides: TiC, SiC, WC, Cr2C3 etc.
*Corresponding author. E-mail: pgupta7@amity.edu 3. Oxides: Al2O3, Cr2O3, TiO2, ZrO2 etc.
446 Jimmy Mehta et al.

Table 1. Difference between various types of coating methods

Characteristic Thermal spray CVD PVD
Operating cost Low to moderate Low to moderate Moderate to high
Process environment Atmospheric to soft vacuum Atmospheric to medium vacuum Hard vacuum
Coating geometry Line of sight Omni-directional Line of sight
Coating thickness Thick, 50 mm-cm Thin to thick, 0.1 mm-mm Very thin to moderate
Substrate temperature Low to moderate Moderate to high Low
Adherence Good mechanical bond Good chemical bond to excellent Moderate mechanical bond
diffusion bond to good chemical bond
Surface finish Coarse to smooth Smooth to glossy Smooth to high gloss
Coating materials Polymers, metals/powder/wire, Metals, ceramics polymers Metals, ceramics, polymers
ceramics

2. Thermal Spray Coating and Its Types

HVOF spraying is a comparatively new, cost effec-

tive and quickly growing thermal spray technique for de-
positing cermets, and metallic and ceramic protective
overlay coatings onto engineering components to allow
them to function under extreme conditions. Several
Figure 1. Basic steps of thermal spray process.
HVOF sprayed coatings have been subjected to corro-
sion testing in seawater, including cermets and anti-cor- ble 3 shows the different substrate material subjected to
rosion alloys [5]. It is capable of producing coatings with D-Gun Technique. Therefore it can be concluded that
high hardness, low oxidation, high abrasion resistance, D-Gun coating can be applied to various materials like
low porosity and high erosion resistance [6]. These are alloys, metals etc. Different powders can be used for
homogeneous and dense, compared to the other types of spray technique exhibits extremely high hardness, su-
thermal sprayed coatings; nevertheless, some residual perb wear resistance with high temperature stability, that
oxides and porosity remain at splat boundaries [7]. is an essential thing for all tribological and high tempera-
Table 2 shows the relevance of HVOF spraying tech- ture erosion applications [10].
nique using diverse powders. From the above table it can Ductile metals like copper, aluminum etc. are most suit-
be concluded that HVOF can be applied to variety of able for cold spraying, but coating of other metals like W, Ta,
substrate material. High velocity of particles during the Ti, MCrAlY, WC-Co, etc. by cold spraying has been also re-
deposition of coating powders, results in desirable char- ported [11]. Figure 2 shows the graph revealing the operation
acteristics such as lower porosity and elevated hardness range for different TSC. It clearly reveals that D-Gun and
of the coating [8]. Liu found out it as the most promising HVOF are the best as they have high density and are easily
technique for developing wear resistant coatings [9]. Ta- applicable to all materials like ceramics, metals, alloys etc.

Table 2. HVOF spraying on different substrate material

Substrate Coating powder Advantage Application
AISI E4340 alloy steel Cr3C2NiCr High deposition efficiency Pressure vessels and gears
Carbon steel alloy Cr3C2-(Ni-20Cr) High density, low porosity, High temperature application
excellent adhesive strength
310S steel Cr3C2-25%Ni-Cr Stable and superior wear Electric furnace, fossil fuel
resistance fired boiler
Superalloys 2014 i NiCrAlY Adherent, non-porous Gas turbine
AlSi substrate Tungsten chromium carbide, High hardness and smooth Industry fan blades
composite NiCrSiB coating surface finish
 Role of Thermal Spray Coatings on Wear, Erosion and Corrosion Behavior: A Review 447

Table 3. Different substrate material subjected to D-Gun technique

Substrate Coating powder Advantage Application
Austentic stainless steel Cr3C2NiCr Enhancing the service life of High temperature application
(AISI 304) component by several times
High speed steel WC-Co and NiCr Hard, dense and wear resistant Steel
coating
SAE 431 Stellite-6 and Stellite 21 Dense coatings Boiler steel, gas turbine
economiser
Superni 718 and AE 435 Al2O3-40% TiO2 Good adhesive strength and low Boiler, IC engines, industrial
superalloys porosity waste incinerators
Sperni 600 alloy Cr3C2-25% NiCr Sound and adherent coating Turbine, boiler and incinerator

Surface topography of the samples was analyzed by us-

ing SEM [16]. It was observed that, at higher temperature
conditions, denser and thicker coating oxide debris layer
was formed on top of WC-25Co. Sudhakar used coating of
Cr3C2-NiCr substrate to improve wear, corrosion and high
temperature oxidation having an application in valves,
evaporators, pressure vessels, fuel tanks materials etc..

4. Effect of Thermal Spray Coating on Erosion

Erosion is the action of surface processes (such as

water flow or wind) that remove soil, rock, or dissolved
Figure 2. Graph revealing the operation range for different
TSC [12]. material from one location on the earth’s crust, then
transport it away to another location.
3. Effect of Thermal Spray coating on Wear Murthy et al. [17] investigated the effect of grinding on
the erosion behavior of a WC-Co-Cr coating deposited by
Wear is the process of removal of material from one both HVOF and D gun spray process. He also compared
or both of two solid surfaces in solid-state contact, when these techniques and found that the surface grinding im-
two solid surfaces are in sliding or rolling motion or proved the erosion resistance. Singh and Bhandari [18] ob-
both. Rate of material removal is generally slow, but served the slurry erosion behavior of D-gun Stellite-6 coated
steady and continuous. and uncoated 13Cr4Ni steels at two different angles (30° and
Badoni and Joshi [13] studied the abrasive wear char- 90°) under a slurry concentration of 5000 ppm. Thakur and
acteristics of high speed steel (HSS) coated by WC-Co Arora [19] studied the slurry and dry erosion behavior of
and NiCr, deposited using detonation gun technique. In- HVOF sprayed WC-CoCr cermet coatings. For experimen-
vestigation was carried at different load and velocity for tal work they used air-jet erosion test rig at an impact angle of
different compositions. It was revealed from the above in- 60 m/s. Dhawan et al. [20] investigated slurry erosion perfor-
vestigation that WC-Co coated steel showed minimum mance of stainless steel (Grade-316), having an application
wear rate at optimized condition. But wear rate is not di- in hydroturbine power plants. HVOF sprayed WC-Co/
rectly proportional to load. It has also been mentioned that NiCrFeSiB coatings on GrA1 boiler tube steel exhibit duc-
uncoated AISI 309 SS suffers significant wear scars along tile and brittle mode of erosion under angular silica sand
with peeling off its contact surfaces in the form of micro- erodent of size 125-180 mm impacted at 40 m/s.
chips under a normal load of about 70N with a sliding ve-
locity of 1 m/s after a total sliding distance of 4080 meters 5. Effect of Thermal Spray Coating on
[14]. Yadav and Mishra [15] studied slurry erosive wear Corrosion
on D-Gun sprayed coatings of SAE 431. It was examined
that fretting damage of the coatings was very minute. Corrosion is a natural process, which converts a re-
448 Jimmy Mehta et al.

fined metal to a more stable form, such as its oxide, hy- Cr3C2-25NiCr coatings were applied through HVOF which
droxide or sulfide. It is the gradual destruction of materi- resulted in production of better coatings than other types
als (usually metals) by chemical and/or electrochemical of thermal spray processes. Singh et. al. [29] studied the
reaction with their environment. oxidation resistance of alloy coating failure caused by the
Mishra et al. [7] observed the hot corrosion behavior stresses generated in protective oxide scales and found
of D-gun sprayed Al2O3-40%TiO2 coating on Superni out that scale cracking and spalling are the key factor to
718 and AE 435 super alloy in aggressive environment influence the lifetime of coatings. Chatha et al. found out
of Na2SO4 + 82%Fe2(SO4)3 at 900 °C. It was concluded that carbide-based coatings provide excellent erosion
that both the coatings deposited on Ni-based super alloy protection, but disagree on the optimum amount of car-
imparted better hot corrosion resistance than the uncoat- bide for maximum erosion resistance [30]. Grewal et al.
ed one. Mishra et al. [21] eval-uated the hot corrosion [31] proposed that D-Gun Spray can be used for devel-
performance of Stellite-6 and Stellite-21 coated as well oping protective coatings of almost any material like ox-
as uncoated SAE 431 steel in aggressive environment of ides, carbides, metals, hard alloys and composite mate-
Na2SO4-82%Fe2(SO4)3 under cyclic conditions at an ele- rial, onto mild steel and other EN series. Kamal et al. [32]
vated temperature of 900 °C for total duration of 50 cy- investigated the microstructure and mechanical proper-
cles. Singh et al. [22] evaluated the corrosion resistance ties of detonation gun sprayed NiCrAlY + CeO2 alloy
of plasma sprayed hydroxyapatite (HA) and HA silicon coatings deposited on super alloys. Den dritic structure
oxide (SiO2) coated AISI 304 substrates. Results indi- formation is depicted by the coating and the micro struc-
cate that hydroxyapatite exhibits higher biocompatibility tural refinement in the coating was due to process on
with human body fluid. Bhatia et al. [23] aimed to inves- T-22 boiler steel (ASTM-SA213-T-22) and studied the
tigate the usefulness of HVOF sprayed 75% Cr3C2-25% cyclic oxidation in air which were conducted at 900 °C
(Ni-20Cr) coating to control hot corrosion of T-91 boiler temperature in the laboratory using silicon car-bide fur-
tube steel at different operating temperatures viz 550, nace. Chawla et al. [33] deposited thin films of nano-
700, and 850 °C. He used the thermosgravity technique structured TiAlN and AlCrN by physical vapor deposi-
to study high temper-ature hot corrosion behavior. Bare tion Shukla et al. [34] tested the oxidation behavior of
super-alloys show spalling and peel of scale. AE 435 HVOF sprayed Cr3C2-NiCr coatings and the bare sub-
super-alloy performed better than Superni 718 and value strate, subjected to high temperature (900 °C) in air for
of a para-bolic rate constant was found out to be 6.7245 500 hours. Results show that there is better adherence to
mg2/cm4 and 39.443 mg2/cm4 respectively [24]. Corro- 310S. Singh et al. [35] revealed various significant fac-
sion resistance of the AISI 304 was found more after the tors influencing wear rate of coatings like impact veloc-
deposition of the HA-SiO2 coatings as compared to that ity, slurry concentration and impact angle. After a fixed
of HA coating [25]. Coated specimens of T91 have shown interval of time, weight loss of sample was found to in-
minimum weight gain at all the operating temperatures crease. Oksa et al. [36] reviewed HVOF thermal spray
when compared with uncoated samples [26]. Main aim of technique, spraying process optimization, and character-
this experiment was to investigate the usefulness of cold ization of coatings, which showed that differences from
sprayed. Ni-50Cr coatings to control hot corrosion of the starting powder to the final coating formation, af-
T22 and SA 516 boiler steels at 900 °C for 50 cycles that fected the coating microstructure and performance. Chatha
resulted in Ni-50Cr coated steels showing lesser weight et al. [9] observed the behavior of Cr3C2-based coatings
gains and the oxide scales which remained intact till the for industrial applications. NiCr offers corrosion resis-
end of the experiment [27]. tance. Mahesh et al. [37] HVOF sprayed Ni-5Al coatings
on Ni and Fe-based super alloy substrates were charac-
6. Effect of Thermal Spray Coating on terized to assess the micro structural features and st-
Wear/Erosion, Erosion/Corrosion and rength in the as deposited condition for their applications
Wear/Corrosion in high-temperature corrosive environment of gas tur-
bine. Wu et al. studied the high temperature properties of
Kamal et al. [28] studied the mechanical and micro thermal barrier coatings (NiCrAlY/YPSZ and NiCrAlY/
structural properties of AISI E4340 alloy steel when NiAl/YPSZ) obtained by D-Gun spraying. The results
 Role of Thermal Spray Coatings on Wear, Erosion and Corrosion Behavior: A Review 449

indicated that the D-Gun sprayed TBCs included a uni- creases in case of NiCr deposited by HVOF. This could
form ceramic coat containing a few micro cracks and a be due to improper spread of coating powder on surface.
bond coat with a rough surface. Sova et al. [38] studied D-Gun showed the best result in all working loads.
the development of multi-material coatings by cold spray HVOF shows better wear resistance under impact wear
and gas detonation spraying. Cold spraying (CS) and and shows less porosity [12]. Powders like Cr3C2-NiCr,
computer-controlled detonation spraying (CCDS) tech- WC-Co, etc. have also shown good results. Kumar et al.
niques were used to fulfill the main objective by the de- [42] observed the microhardness and porosity level, which
velopment of multi-functional multi material protective increased up to 0.93% while using HVOF spray coating
coatings. Hard facing has also proved as a better option in case of
tiller blades, which are used in cultivation, and requires
7. Discussions replacement after short period of time for effective and
efficient working [43]. Coatings like chromium, tung-
Thermal spraying processes are studied which is the sten carbides etc. exhibit high hardness depending only
most suitable and effective surface engineering technol- on how the coating layer has been deposited i.e. (nano-
ogy. It is widely used to apply wear, erosion and corro- metric or micro-metric) on the substrate material [43,44].
sion resistance/protective coatings for various kinds of D-Gun, HVOF, Plasma Spray etc. are the techniques,
industrial applications. It was observed that the coatings which are frequently being used and are easily available
offer excellent corrosion and oxidation resistance, high not only in India but also all over the world as much of
melting point, high hardness, strength and wear resis- the literature studied is out of India. Boron steel (a me-
tance at high temperature [39]. The lamellar structure dium carbon steel) having high hardness can also be used
and the presence of cracks and impurities could reduce as base material with and without coating. Uptil now it
the thermal conductivity of the ceramic coat. A dense has only been used with hardening processes and no
coating with less porosity and inclusions were the re- work with coating has been tried or done. Boron steel has
sult of HVOF process. Average bond strength and micro
hardness of the coatings was found to be 58 MPa and
697–920 HV respectively. The hardness of coatings on
three different super alloy substrates was measured and it
was in the range of 210–272 HV. Average bond strength
and surface roughness of the as sprayed coatings were
found out to be 42.62 MPa and 9.22-9.45 mm respec-
tively [40].
As far as Cold Spray was concerned, the separate in-
jection of each powder into different zones of the carrier Figure 3. Cross-sectional image of as-sprayed coating.
gas stream was applied. Cu-Al, Cu-SiC, Al-Al2O3, Cu-
Al2O3, Al-SiC, Al-Ti and Ti-SiC coatings were sprayed
successfully on the base material.
Methods and tools for controlling the spray process
were presented and their use in optimizing the coating
process [41]. In order to improve the adherence and oxi-
dation resistance of coatings, rare earth elements (La, Zr,
Ce, Y, etc.) were added in the coating powder composi-
tion. Addition of rare earth metals lead to the conclusion
that the scale nucleates at reactive element oxide parti-
cles on the surface.
Figure 4 shows comparison of different coating pow-
Figure 4. Comparison of different coating powders deposited
ders deposited by D-Gun and HVOF with that of uncoat- by D-Gun and HVOF with that of uncoated sub-
ed substrate material. As the load increases wear rate in- strate material.
450 Jimmy Mehta et al.

applications in harvesting instruments, spades, washers ramic Society, Vol. 44, No. 2, pp. 56-62 (2008).
etc. Hence, this material can be used for testing and ex- [4] Balan, K. N., Bapu, B. R. R., Rajan, A. J. and
perimental work. A few literature reports are also avail- Manimaran, “Enhancement of Surface Property by
able on boron steel. Thermal Spray Coating Technique – A Review,” Pro-
Shakoor [45] compared the properties of Ni-B and ceedings of 10th IRAJ International Conference, pp.
Ni-B-ZrO2 coatings in their as deposited state to eluci- 29-31 (2013).
date the effect of ZrO2 addition on structural, surface, [5] Chatha, S. S., Sidhu, H. S. and Sidhu, B. S., “Charac-
thermal and electrochemical properties of binary Ni-B terization and Corrosion-erosion Behavior of Carbide
coatings. It is noticed that Ni-B coatings are amorphous Based Thermal Spray Coatings,” Journal of Minerals
in their as deposited state while addition of ZrO2 signifi- Materials Characterization & Engineering, Vol. 11,
cantly improves the crystallinity. No. 6, pp. 569-586 (2012). doi: 10.4236/jmmce.2012.
116041
8. Concluding Remarks [6] Bhatia, R., Sidhu, H. S. and Sidhu, B. S., “High Tem-
perature Behavior of Cr3C2-NiCr Coatings in the Ac-
The present paper is a review on the role of TSC on tual Coal-fired Boiler Environment,” ASM Interna-
wear, erosion and corrosion behavior. Various types of tional (ASM) and The Minerals, Metals & Materials
TSC along with industrial applications of boron steel has Society (TMS), Vol. 2E, pp. 70-86 (2015). doi: 10.
also been discussed. Following are the important con- 1007/s40553-015-0045-x
cluding remarks of the paper: Coatings play an important [7] Mishra, N. K., Kumar, N. and Mishra, B. S., “Hot Cor-
and vital role in protecting/layering the substrate mate- rosion Behavior of Detonation Gun Sprayed Al2O3-
rials and alloys from wear, erosion and corrosion [1]. A 40TiO2 Coating on Nickel Based Superalloys at 900
lot of work has can be done in this field to study the me- °C,” Hindawi Publishing Corporation Indian Journal
chanical and micro-structural properties with reference of Materials Science, Article ID 453607 (2014). doi:
to the applied coatings. Optimization techniques like 10.1155/2014/453607
Taguchi Method, ANNOVA, etc. can also be used to ana- [8] Bhatia, R., Singh, H. and Sidhu, B. S., “Hot Corrosion
lyze the results. D-Gun spray process and HVOF pro- Studies of HVOF-sprayed Coating on T-91 Boiler Tube
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available and not so costly. Nano-structured powder ma- Materials Engineering and Performance, Vol. 23, pp.
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this particular area but still a lot of efforts and different [9] Chatha, S. S., Sidhu, H. S. and Sidhu, B. S., “Charac-
combinations of coatings has be explored. terization and Corrosion-erosion Behavior of Carbide
Based Thermal Spray Coatings,” Journal of Minerals
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