A Comparative Study of the Microabrasion Wear Behavior of CoNiCrAlY Coatings Fabricated by APS, HVOF, and CGDS Techniques

The current study focuses on the microabrasion wear and microstructural properties of CoNiCrAlY coatings fabricated on nickel-based superalloy substrates using atmospheric plasma spraying (APS), high-velocity oxygen fuel (HVOF), and cold gas dynamic spraying (CGDS) methods. The microabrasion tests were performed on the samples for different durations in order to understand the wear mechanism of thermally sprayed coatings and influence of the coating microstructure on the wear mechanism. The microstructures of as-sprayed coatings and wear mechanisms on the worn coatings were investigated. Initial surface topography was examined using a surface profilometer. Coating hardness measurements were performed with a microhardness tester. The lateral fracture was observed as the wear mechanism on the samples. The wear resistance of the coatings has changed with the surface features of the samples depending on the coating production process.