High-temperature tribological performance of functionally graded Stellite 6/WC metal matrix composite coatings manufactured by laser-directed energy deposition

Abstract Wear-driven tool failure is one of the main hurdles in the industry. This issue can be addressed through surface coating with ceramic-reinforced metal matrix composites. However, the maximum ceramic content is limited by cracking. In this work, the tribological behaviour of the functionally graded WC-ceramic-particle-reinforced Stellite 6 coatings is studied. To that end, the wear resistance at room temperature and 400 °C is investigated. Moreover, the tribological analysis is supported by crack sensitivity and hardness evaluation, which is of utmost importance in the processing of composite materials with ceramic-particle-reinforcement. Results indicate that functionally graded materials can be employed to increase the maximum admissible WC content, hence improving the tribological behaviour, most notably at high temperatures. Additionally, a shift from abrasive to oxidative wear is observed in high-temperature wear testing.