Bull. Mater. Sci.

(2024)47:121  Indian Academy of Sciences

https://doi.org/10.1007/s12034-024-03212-5 Sadhana(0123456789().,-volV)FT3](012345
6789().,-volV)

Study on high-temperature erosive wear behaviour, surface

roughness and scratch resistance of NiCrAlY-based
composite coating

K P JHANSI LAKSHMI1, C R RAGHAVENDRA1,* , IRAPPA SOGALAD2

and S BASAVARAJAPPA3
1
Department of Mechanical Engineering, Government Engineering College, Haveri 581110, India
2
University BDT College of Engineering, Davanagere 577230, India
3
Indian Institute of Technology, Dharwad 580008, India
*Author for correspondence ([email protected])

MS received 3 August 2023; accepted 20 January 2024

Abstract. This study concentrates on NiCrAlY-based coating with nano-boron carbide and cenosphere particles. The
composition of NiCrAlY, B4C and cenosphere are maintained the same for all the samples. The plasma spray technique is
used for coating. The erosive wear is carried out for different impingement angles of 30, 60, 75 and 90 at 900C. The
morphology of coating before and after erosive wears is studied using scanning electron microscopic analysis. Further, the
study is carried out on surface roughness, scratch resistance and coefficient of friction of the eroded surface of the
samples. The significant erosive wear resistance is reported for an impact angle of 60 followed by 30. The surface
roughness results reveal the formation of deep craters and the ploughing effect of material on the coatings. The scratch test
and COF show the presence of coating and the brittle nature of the failure of the coating.

Keywords. Plasma spray; NiCrAlY composite coating; erosive wear; surface roughness; scratch test; coefficient of
friction.

1. Introduction friction. The worn-out or eroded surface roughness was also

found to be useful in determining the tribo-performance of the
The plasma sprayed coating was found to be more effective in surfaces [11]. These three distinct characteristics are also
the area of high-temperature application components viz., considered as parameters in multi-objective optimization by
turbine, condenser, evaporator. The impact of solid and Sardar and Das [12]. Elemuren et al [13] concentrated on the
inserted particles at higher temperatures and velocity on effect of particle concentration on erosion–corrosion by
components results in severe damage due to hot spots. This surface roughness of 90 AISI 1018 steel elbow. The surface
will lead to failure of the material and functional ability of the roughness and coating adhesion are certainly to change when
components exposed to high-temperature environment [1]. the surfaces are subjected to wear. The change in these
The NiCrAlY coating has shown the potential ability to parameters is even more at high-temperature environments.
provide better resistance to erosion, corrosion and oxidation The present work is majorly concentrated on the study of the
[2]. Due to the lower hardness of the NiCrAlY particles erosive wear behaviour of NiCrAlY/0.15B4C/0.5cenosphere
compared to carbides, the hard secondary phase particles are composite coating at an elevated temperature of 900C.
also used in the matrix. A few of these particles used with Further investigation is carried out on the study of surface
NiCrAlY are Al2O3 [3], Wc-Co [4], YSZ [5], B4C [6], CeO2 roughness, coefficient of friction and adhesive strength on the
[7] and many more. The surface thus achieved with secondary post-erosion surfaces.
phase particles has shown enhanced functional properties
[8,9]. Mathapati et al [10] found 71% higher erosive wear
resistance with NiCrAlY-25WC-Co/cenosphere composite 2. Experimental
coating compared to the bare substrate. They have also
observed that the erosive wear was found to increase with the 2.1 Details of coating material and method
increase in temperature and the nature of wear is brittle in the
mechanism. The tribological characterization of surfaces is In the present study the MDN321, purity: 99% (Mishra
generally concentrated on wear resistance and coefficient of Dhatu Nigam Limited, Hyderabad, India), is considered as
121 Page 2 of 12 Bull. Mater. Sci. (2024)47:121

Table 1. Mass fraction of NiCrAlY powder. Table 3. Erosive wear test parameters.

Sl. no. Constituent Wt. % Sl. no. Test parameters Description

1 Cr 22 1 Erodent Al2O3
2 Al 10 2 Erodent size APS (lm) 50
3 Y 1 3 Particle velocity (m/s) 35
4 Ni Balance 4 Erodent feed rate (g/min) 2
5 Impact angle (deg) 30, 60, 75, 90
6 Temperature (C) 900
7 Test time (sec) 600
the substrate material. The samples for erosive wear tests
are prepared in the size of 25 9 25 9 5 mm3 as per ASTM
G-76 standard. Based on mass fraction, three coating
powders are used: 80%NiCrAlY; APS 150 lm, 15%B4C; difference in weight measured before and after wears. The
APS 40 nm, purity: 99% (Reinste Nano Ventures Pvt. Ltd. test parameters are as shown in table 3. The surface
New Delhi, India) and 5% cenosphere; APS 50 lm (Petra roughness of the samples before and after erosions is carried
Build care Products, Waghawadi, Bhavnagar, India). These out by Mitutoyo surftest SJ-210 having a diamond skid
particles are mechanically blended before coating. The stylus with 370 lm and 16 mm travel for each reading with
mass fraction of NiCrAlY powder is given in table 1. The a stylus speed of 0.50 mm s–1. The scratch test before and
uniform distribution of NiCrAlY, B4C and cenosphere after the erosive wears on the coated samples is tested by
particles is witnessed with the micrograph image of the scratch test rig TR-101, with a diamond stylus 120 and
powder blend shown in figure 1. The substrate samples are 200 lm nose radius (Ducom, Bangalore, India). The ramp
grit blasted before subjecting it to plasma spray coating. load is applied for all the scratch tests by varying load from
The detailed parameters of plasma spray coating are given 0 to 20 kg with a scratch length of 10 mm. The traction
in table 2. force and coefficient of friction (COF) are recorded as
shown by the system.

2.2 Characterization of the as-sprayed coatings

3. Results and discussion
As per the standard metallographic techniques, the
microstructural studies of the coated samples are carried 3.1 Microstructure of coating
out. The coating particles of NiCrAlY powder and coating
surfaces are analysed by scanning electron microscope The SEM micrograph of NiCrAlY/B4C/cenosphere com-
(SEM) attached with energy-dispersive X-ray spectroscopy posite coating is presented in figure 2a. It is evident that the
(EDX) (Model: JSM-6010 resolution of 3.0 nm. Make: blended coating particles have exhibited splat structure due
JEOL Pvt. Ltd. Tokyo Japan). to high temperature in plasma spray. This high temperature
The erosion tests were conducted on the air erosion test makes them melt and form molten droplets and impact on
rig (Ducom, Pvt. Ltd. Bangalore, Karnataka, India). The the target with high velocity. In the present coating, three
detailed erosion wear test parameters are given in table 3. regions are observed with fully melted particles which are
The tests were carried out in three trails and an average of dominated by dark grey colour, partially melted with light
nearby two values are considered. The erosive wear is grey colour and unmelted particles at few locations. These
calculated in terms of material loss by considering the unmelted particles presence may be attributed to the nano
size of the particles and time fraction during the coating.

Table 2. Parameters of the plasma spray technique.

Sl. no. Gun 3MB

1 Nozzle GH Pressure (Psi) Flowrate (SCFH)

Argon 100-120 100-115
Hydrogen 50 15-18
2 Current 500Amps:60-65 Volts
3 Powder feed 100-120 gm/min
4 Spray distance 4-6 inch
5 Temperature 10000C at tip of nozzle
Bull. Mater. Sci. (2024)47:121 Page 3 of 12 121

Figure 1. Morphology of NiCrAlY/B4C and cenosphere particles as blended.

The fully melted splats are predominated on the coated micrograph of the coating and substrate is shown in
surface, which indicates that most of the particles are figure 2c. The coating thickness is found to be 280.8 lm and
melted and splatted on the surface of the substrate. It is also good adhesive strength is also noticed.
observed that the coating has a lamellar structure with
minimum void and microcracks. Gell et al [14] found a
similar lamellar microstructure with fully melted splats 3.2 High-temperature erosive wear
along with unmelted zones in the plasm-sprayed coating
surface. Wu et al [15] found a lamellar structure for The erosive wear tests were carried out at a temperature of
NiCrAlY coating by plasma spray technique with voids and 900C for all the samples exposed to different angular
oxide inclusion along with unmelted particles. The presence impacts. The erosion wear rates of coated and uncoated
of cenosphere is also observed with white colour splats on specimens for different impingement angles of abrasive are
the coating. The distribution of the NiCrAlY and boron shown in figure 3. The impact angles of 30, 60, 75 and 90
carbide particles was also found uniform with light and dark are considered at a velocity of 35 m s–1. In addition, the
grey colour variations in the SEM micrograph image (fig- significance of coating on the substrate is highlighted in
ure 2a). Figure 2b shows the EDS analysis of the composite terms of the percentage increase in erosive wear resistance
coating from which the presence of blended particle com- in comparison with the uncoated samples. The erosive wear
position can be seen. The mass quantitative analysis reveals results of coated and uncoated samples are shown by the
the dominance of oxide and Ni particles. The Yttrium is green and yellow colours, respectively. It is also observed
fairly stable in air and is also found its presence by 0.75% in that the 60 impingement angle has shown maximum
the composite coating surface. The lower peaks at multiple resistance to removal of material subjected to erodent
sites of Yttrium are highlighted. The image analyzer impact. The results reveal that the erosive wear resistance
has increased significantly for all the impact angles
121 Page 4 of 12 Bull. Mater. Sci. (2024)47:121

Fully melted

Unmelted particles
Cenosphere

Partially melted particles

b Element Mass %
B 3.43
C 10.43
O 39.02
Al 14.82
Si 12.55
K 0.35
Ca 0.34
Cr 5.45
Ni 12.86
Y 0.75
Total 100.0

Substrate Coating

Coating thickness
280.8 µm

Figure 2. (a) SEM micrograph images of coating, (b) EDS analysis of composite coating and corresponding element
mass basis analysis, and (c) image analyzer showing the coating thickness and substrate.

compared to uncoated samples. The maximum erosive wear increased the erosion wear rate. Ramachandran et al [17]
resistance is found to be 223.07% for an impact of 60. This found similar results for various impact angle conditions.
reveals the resistance offered by the NiCrAlY/B4C/ceno- They found better erosive wear resistance for the oblique
sphere composite coating. Under similar erosive wear impact conditions.
conditions, a minimum erosion rate is observed for an
impact angle of 60 followed by 30. The maximum erosion
rate is noticed for 90 impact angle, meanwhile it has shown 3.3 Surface roughness of the eroded surface as a function
improved resistance by 185.83% compared to uncoated of impact angle
samples. Mishra et al [16] found a higher erosion rate for a
90 impact angle compared to 30 for the NiCrAlY coating. Meanwhile the surface roughness of the bare sample and
The increase in the impact angle from 60 to 90 has composite-coated samples are measured and found to be
Bull. Mater. Sci. (2024)47:121 Page 5 of 12 121

12
Erosion rate x10-4 in g/g

10

8 Percentage increase in erosive wear resistance

185.83%
147.15%
6
176.75%

223.07%
4

0
30 60 75 90
Impact angle (degree)
Figure 3. Results of erosion rate of coated and uncoated samples.

Figure 4. Surface roughness results as a function of impact angles at (a) 30, (b) 60, (c) 75 and (d) 90.
121 Page 6 of 12 Bull. Mater. Sci. (2024)47:121

a) b) Detached splats

Micro cuttings

c)

Deformation of coating

Figure 5. SEM micrograph image of worn surface at 30 impact angle.

0.779 and 2.052 lm, respectively. The oblique impact the zone A are carried away along the direction of the
angles have shown minimum worn-out surface area com- erosion. The lower erosion rate is observed for the impact
pared to the 90 impact angle. The eroded place in the angle of 60 compared to other impact angles. This is due to
samples is highlighted by three zones A, B, and C, as shown the higher resistance offered by the coating particles at zone
in figure 4a–d. The innermost zone A with black colour B restricting the further erosion of the coating. The
indicates the major impact area, where more material is roughness values of Ra were found to vary from zones A to
removed. In the case of a 30 impact angle, the material C, as shown in figure 4b. This is due to the restriction in
removal is carried on along the direction of impact zone B and the carry forward of the eroded particles in zone
(figure 4a). The affected zone is highlighted in an oval C. This is also witnessed by the higher Rz value of 58.98 lm
shape. It means that the eroded material is taken for a dis- at zone A and the minimum variation between zones B and
tance from the impacted area. The removed material seems C. The area of contact kept decreasing with an increase in
to be rolled over to the subsequent zone B. This zone B is an the impact angle. This is highlighted in figure 4c for an
intermediate zone which lies between the core of impact impact angle 75. The more protuberance is observed at
and outer zone C, which has more carried away material by zone B and the higher core impact area A is observed due to
the impact of particles. Zone C will have loose and mini- the lower contact area between the impact particle and with
mum carried-away particles on the coated surface. These surface. A higher crater at the impact core area is seen with
surface roughness results are also supported by Mishra et al a dark black colour, which highlights the more material
[2], where the NiCrAlY and Ni-20Cr coatings have found removal. This is also supported by the Ra and Rz values of
similar results. This is also supported by the surface 15.63 and 68.23 lm shown at the core and bulged area,
roughness value of Ra and Rz at three zones. The maximum respectively. This is due to a higher impact angle restricting
value of Ra is noticed at the centre of the impact of particles the eroded and impact particles from brushing on the sur-
at zone A. The Ra and Rz values on the other two zones B face of the coating. This is the reason for the lower Ra and
and C are found to be similar as the particles impacting at Rz value at zone C. The severity of impact is maximum for
Bull. Mater. Sci. (2024)47:121 Page 7 of 12 121

a) b)
Plastic deformation of the material

c)

Direction of erosion

Figure 6. SEM micrograph image of worn surface at 60 impact angle.

an impact angle of 90 due to the perpendicularity of the erodent on the coating surface. The rubbing action of
particle impact on the surface. This has led to deeper and erodent leads to plastic shear and ploughing of the material.
narrower core zone A surrounded by protuberance area B. The repeated erodent impact makes the material to be
This is the reason for the maximum Rz value of 82.73 lm, removed by the surface. The repeated impact of erodent
which reflects the distance between the peak and the valley. particles leads to the formation of fragmentation of material
[17]. This fragmentation further leads to minor pit forma-
tion. This is evident from the figure 6a and c. The rubbing of
3.4 Morphology of the worn surface the material along the direction of erodent impact is high-
lighted in figure 6c. These scratches formed on the surface
Figure 5a–c shows the worn surface at an impingement witness the formation of the grooves and plucking of the
angle of 30. It is observed that the coating removal by material in the direction of erodent impact which may be
erosion is dominated by microcracks and ploughing. The caused by the lamellar microcracking and plastic defor-
deformation of the material on the eroded surface is by the mation. The coating at this angle of impact has shown better
detachment of splats by the impact of particles. The nature resistance, as most of the removed materials always fall
of deformation shown in the figure 5b and c shows the along the path of impact. Interestingly, the erosion rate for a
ductile nature of failure. Similar observations were drawn 60 impact angle has been found minimum compared to a
by Mishra et al [16] for the impact angle of 30 of NiCrAlY 30 impact angle. These results are also supported by
coatings. The shallow angle of impact on coating leads to Kumar and Npandey [19], where they found 60 impact
the failure of the material by the ductile nature of the angle found a better erosion rate compared to both 30 and
mechanism [18]. 45 impact angles.
The worn surface of the coating by the impact angle at The higher erosion rate is noticed for the impact angle of
60 is shown in figure 6a–c. The change in the angle of 75 compared to 30 and 60 impingement angle.
impingement of erodent to 60 has found minor changes in Figure 7a–c shows SEM micrograph images of the worn
the nature of material failure. This is due to the shallow morphology of coating with an impact angle of 75. The
impact angle and provides higher surface area of contact for images show the craters and raised lips at various sites
121 Page 8 of 12 Bull. Mater. Sci. (2024)47:121

a)

Plucked out particles

Moving away from
Impingement
the surface
Eroded particles of erodent
75˚

Crater

b) c)

Crater Eroded particles

Figure 7. SEM micrograph image of worn surface at 75 impact angle.

along with eroded particles. The repeated impact of erodent material by gouging of particles is attributed to the harder
on the surface leads to plastic deformation of the surface. particles on the coated surface. Hence, the failure of the
This is even more at higher temperature limits of 900C. material mechanism is dominated by ductile and minor
The erodent impacting on the surface basically raised above brittle nature. This is also witnessed by the sharp lips pre-
the surface and deforms by the consecutive impact of the sent in the craters. This is due to the higher impact force
erodent [20]. The rise of particles is more in case of a higher experienced by the coating surface by the blitz effect of the
angle of impingement, which leads to form the craters. The erodent particles. At a higher temperature of 900C, these
number of craters and the size of these craters increases hard erodent removes more material from the coating sur-
further. This increases the severity of the plastic deforma- face. This results in significant crater formation and further
tion [2]. This is also evident from figure 7c, with more deepens the crater and material removal. These deep craters
craters and eroded particles adjacent to the craters. These and rise in lips are found to be absent in case of shallow
craters leave void places at the impacted site. As the angle of impact in 30 and 60. This is the reason for greater
impingement angle is increased to 90, the severity of erosion wear for the impact angles of 75 and 90.
material failure increases. This is the reason for a greater
number of craters, seen in figure 8a and b. These craters are
mainly formed by plucking of the particles. Due to the 3.5 Scratch analysis of worn surface
incident angle being normal to the direction of surface, the
rubbing action of the particles and splats are hardly seen. The scratch test is used to find the adhesion ability of the
The depth and width of the craters are observed in figure 8c coating with substrate material after exposing composite
and magnified images in figure 8d. This is also supported by coating to high-temperature erosion wear. The magnitude of
the surface roughness Rz values shown in figure 4d. The the traction force during the scratch test is discussed with
continued impact of erodent at a perpendicular direction respect to COF experienced during the scratch. At elevated
leads to a failure of the material in excess compared to the temperature, the hardness of the steel decreases significantly
rest of the angle of attack. This has led to cracks and [18]. The coating on these conditions effects the adhesive
maximum material removal [21]. Thus, the removal of strength greatly. Figure 9a–d shows the results of traction
force (TF) with respect to the stroke length of 10 mm. The
Bull. Mater. Sci. (2024)47:121 Page 9 of 12 121

a) b)

Craters

c) d)
Fragments

Crack
Width of the crater

Figure 8. SEM micrograph image of worn surface at 90 impact angle.

micrograph images during the scratch at three different plucking or side way movement of the material in the path
zones A, B and C are also plotted as given by the scratch of scratch. Hence, the minimum traction force resulted for
test rig TR-101. Interestingly, all the three zones of coatings the 90 impact angle compared to shallow impact angles.
effected by the erosion wear at elevated temperature of Thus, the magnitude of this traction force indicates the
900C have shown better resistance to the scratch. This adhesion of the coating with the substrate material [22]. The
indicates the better adhesion of the NiCrAlY/nano B4- variation in the traction force at different zones for the
C/cenosphere coatings with MDN321 substrate material impact angle of 90 is observed. In particularly lower
even after erosion effect. This also witnesses the strength of traction force at zone C. It indicates that the material
the composite coating. The maximum traction force is removed by the impingement of the erodent has resulted in
reported for the impact angle of 60 followed by 30. the loose particle assembly at zone C. Thus, the minimum
The undulations are observed in the zone A of figure 9a traction force resulted for the 90 impact angle compared to
(highlighted in red color) and figure 9b shows the resistance 30 orientation of the erodent impingement. The higher
offered by the coating for the indenter movement. This traction force resulted for the harder and tougher substrate
leads to minor change in the path of indenter movement. material [23]. They may also depend on the elastic modulus
This is attributed due to the presence of harder particles in and COF. Blees et al [22] also found that the adhesion
the zone A. The presence of coating material along the path strength depends upon the COF during the scratch test.
of the scratch highlighted in figure 9b shows the resistance Figure 10a–d shows the results of COF along the stroke
and adhesive strength of the coating. This is the reason for length of the scratch. The maximum and minimum average
higher traction force for impact angle of 60. In case of 75 COF are reported for the impact angle of 60 and 75,
impact angle (figure 9c), the deviation in the traction force respectively. The COF of 0.3254 and 0.177 is reported in
results for each zone are varied. This is even more in case of the zones of A (60), and C (75), respectively. The higher
90 impact angle. The consecutive variation in the peak and COF indicates the higher resistance offered by the particles
throughs in figure 9d witnesses the abrasion experienced by in the coating surface. This also indicates the nature of
the indenter during the scratch. This is due to the reason of failure by brittle fracture.
121 Page 10 of 12 Bull. Mater. Sci. (2024)47:121

a) b)

@ Zone A A

@ Zone B h
Width of scar B
@ Zone C
C

c)
d)

A A
Coating
B Scratch B

C C

Figure 9. Results of traction force against stroke length and micrograph images at different zones of the eroded
surface.

Meanwhile, the brittle fracture experienced by the back Al-Motasem et al [25]. Thus, the higher COF indicates the
of the indenter tip is not greatly influenced by COF [24]. ploughing of the material on the surface. This ploughing of
The drastic increase in COF and peaks observed in material is the result of higher dislocation density [25,26].
figure 10b indicates the failure of the material due to an Hence, the lower COF for the higher angle of impact
increase in the stresses. This leads to delamination of the indicates the (figure 10c and d) lower resistance offered for
material in the composite coating. This is also supported by the scratch movement by the tip of the indenter. This can
Bull. Mater. Sci. (2024)47:121 Page 11 of 12 121

a) b)
Increase in the COF peak

c) d)

Figure 10. Results of COF against stroke length for different angles of impact.

also be related to the presence of more loosely packed • The erosion wear mechanism is dominated by the
particles concentrated on the eroded place. The higher rate ploughing, detachment of peaks and formation of
of material removed at 90 impact angle has created more craters.
lips, shown in figure 8c and d. This may also result in lower • Severe material loss in case of 90 impact angle is
COF. Subhash and Zang [27] found that the adhesive reported due to the deep crater formation in clusters
strength depends on the interfacial friction and ploughing on the surface of coating. This is due to the high
effect on the geometry of the material. Meanwhile at 60 impact energy processed by the erodent.
impact angle, the particles are expected to be more adhering
to the surface of coating even after higher impingement of
erodent.

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