Wear Resistant Coatings, Tungsten Carbide & Ceramic Coatings

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There are many types of wear mechanisms including adhesive, abrasive, erosive, cavitation, and fretting. In many cases wear can occur from a combination of these mechanisms. Understanding the factors that are causing wear to occur is very important to engineering the proper wear resistant coatings. Fortunately with the ability of thermal spray to work with an almost limitless number of materials, well engineered wear resistant coatings can usually be produced to solve even some of the most complex wear issues.

When engineering wear resistant coatings, Thermal Spray Technologies uses its strong expertise in materials engineering and the wear resistant properties of thermal sprayed materials. The combination of this knowledge provides application specific solutions to our customers wear problems.

Coating Materials

Some of the materials Thermal Spray Technologies commonly uses to provide wear resistant coatings include ceramics such as carbides and metal oxides. Carbide coatings are produced in the form of cermets (ceramic and metal) they provide hardness and wear resistance coatings similar to solid sintered carbide components like carbide metal cutting tools. Metal oxides such as chromium oxide are also very hard and are very resistant to chemical attack so they can be an ideal solution when wear and corrosion are both present. Several metals and even some plastics are also used to provide wear resistant coatings.

  • Carbide coatings are produced in the form of cermets (ceramic and metal). Cermets provide hardness and wear resistance coatings similar to solid sintered carbide components like carbide metal working tools.
  • Tungsten carbide is an especially effective wear resistant coating, as it offers exceptionally high hardness levels (maximum 74 HRC hardness). Tungsten carbide is highly resistant to extreme temperatures below 650°C (1200°F) and corrosion.
  • Metal oxides such as chromium oxide are also very hard and are very resistant to chemical attack so they can be an ideal solution when wear and corrosion are both present.
  • Several metals and even some plastics are also used to provide wear resistant coatings.

wear resistant coatings hardness graph

wear resistance coating vs. hard chrome platting graph

Materials

Wear resistant coatings can be deposited on several different materials using thermal spray. Almost all metals can be coated and even many heat sensitive materials such as carbon fiber composites and some plastics can be successfully coated.

Examples

Highly complex components such as jet engine compressor blades are coated for wear resistance. Even simple parts such as bolts used in agricultural combines are coated with carbide coatings to greatly extend life of the bolts and prevent machine damage from the detachment of high speed rotating parts.

wear resistance coatings on jet engineswear resistance coatings on agricultural combines

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