Corrosion and wear behavior of Ni-based alloy coating deposited on steel substrate by thermal flame spraying

In this study, Ni-based alloy coating was sprayed on steel substrate using a thermal flame spraying. Wear track morphology and damaged surfaces of Ni-based coating and steel substrate after polarization were examined by Scanning Electron Microscopy (SEM), equipped with an Energy-Dispersive X-ray Spectroscopy (EDS) analyzer and X-ray mapping. The electrochemical corrosion resistance of both uncoated and coated steel was studied in a 3.5% NaCl solution. Moreover, the friction and wear resistance of the as-sprayed coating and steel substrate were evaluated under a 4N load against an alumina ball in dry conditions.The average value of COF 0.720 and corrosion current density 1.554 µA/cm² of bare substrate was improved to 0.501 and 0,1250 µA/cm² respectively, of the coated samples.These results indicate the beneficial effect of the as-sprayed coating on the wear resistance and corrosion performance of the steel substrate.