Wear 249 (2001) 592600

Effect of grinding on the erosion behaviour of a WCCoCr coating

deposited by HVOF and detonation gun spray processes
J.K.N. Murthy
a
, D.S. Rao
b
, B. Venkataraman
a,
a
Defence Metallurgical Research Laboratory, P.O. Kanchanbagh, Hyderabad 500058, Andhra Pradesh, India
b
International Advanced Research Centre for Powder Metallurgy and New Materials, Hyderabad 500005, Andhra Pradesh, India
Received 7 October 2000; received in revised form 23 April 2001; accepted 8 May 2001
Abstract
There is a growing interest on the use of thermal spray coatings for a variety of wear resistance applications due to the several advantages
it offers. WCCo coating is widely used for wear resistance applications. It is known that addition of Cr to WCCo improves binding
of the metallic matrix with the WC grains and provides better wear resistant coating. Thus, WCCoCr is considered to be a potential
wear resistant coating material as compared to WCCo coating. The thermally sprayed carbide coatings are in general surface nished
by machining or grinding after the coating process. Therefore, it is imperative to understand the inuence of the nishing operation on
the characteristics and performance of carbide coatings. This work aims at investigating the effect of grinding on the erosion behaviour
of a WCCoCr coating. As a part of this work a comparison has also been brought out between two high velocity coating processes
namely high velocity oxy-fuel (HVOF) and detonation gun spray process (DS). A WC10Co4Cr powder has been sprayed on a medium
carbon steel using the above mentioned high velocity spray processes. Some of the coated specimens were further ground by a diamond
wheel with controlled parameters. The coating in both as-coated and as-ground conditions has been tested for solid particle erosion
behaviour. The erosion experiments were carried out using an air-jet erosion test rig with silica erodents at a velocity of 80 m/s. It has been
found that surface grinding improved the erosion resistance. This work presents detailed characterisation of the WCCoCr coating in
both as-coated and as-ground form. A detailed analysis indicates that the increase in residual stress in the ground specimen is a possible
cause for the improvement in erosion resistance. 2001 Elsevier Science B.V. All rights reserved.
Keywords: High velocity oxy-fuel; Detonation gun spray; Hard chrome replacement; WC10Co4Cr; Erosion; Grinding; Residual stress
1. Introduction
Thermally sprayed coatings are widely used in various ap-
plications to combat various surface degradation processes
such as wear, erosion, corrosion, etc. Air craft, textile, au-
tomobile and mining are some of the areas where thermally
sprayed coatings are extensively used for various advantages
that this class of coating offers [1]. Carbide coatings are
sometimes preferred for tribological applications. Among
various carbides, tungsten carbide and chromium carbides
are most preferred. While the former is used at temperatures
up to 500

C, the later is used for higher temperature (up to

800

C) applications. The carbide coatings are coated by air

plasma spray (APS) or high velocity coating processes [2].
Although APS coatings are considered to be cheaper, con-
siderable decarburisation of tungsten monocarbide (WC) to
di-tungsten carbide (W
2
C) as well as metallic tungsten oc-
cur [3,4]. The presence of oxygen in air plasma spraying is

Corresponding author. Fax: +91-40-4341439/0683.

E-mail address: bvraman@eth.net (B. Venkataraman).
found to favour these transformations and to promote the nu-
cleation of oxy carbides in considerable amount which are
undesirable for wear resistance. Also, higher porosity and
lower hardness is a major disadvantage in the APS coatings
for some of the tribological applications. The high velocity
processes such as high velocity oxy-fuel (HVOF) and deto-
nation gun spray (DS) processes minimise decomposition of
the carbide phase due to lower heat enthalpy and shorter du-
ration involved in the coating processes. In addition, higher
particle velocity during deposition provide several advan-
tages such as lower porosity, higher bond strength and hard-
ness. Thus, carbide coatings coated by high velocity thermal
spray processes is found to be the bill-of-material for wear
prone applications, and the use of various high velocity coat-
ing processes for carbide coatings are explored extensively.
The carbide coatings are also being considered as a viable
replacement for hard chrome plating in abrasion, sliding and
erosion applications owing to the strict environmental reg-
ulations [58]. As mentioned earlier, the decomposition of
WC has to be minimised. It has been found that chromium
addition to WCCo inhibits the decomposition of WC and
0043-1648/01/$ see front matter 2001 Elsevier Science B.V. All rights reserved.
PII: S0043- 1648( 01) 00682- 2
J.K.N. Murthy et al. / Wear 249 (2001) 592600 593
also prevents formation of metallic tungsten. The chromium
addition also improves the binding of carbides to the ma-
trix, thereby improving the erosion resistance as compared
to WCCo coatings [3].
The thermally sprayed coatings in general result in
higher surface roughness. In carbide coatings especially,
the surface roughness in the as-sprayed form is higher than
the acceptable limits for many applications. Therefore, the
carbide coating surfaces are to be nished suitably in or-
der to achieve desirable surface roughness. The nishing
operation, however, may alter the coating characteristics.
Therefore, it is imperative to know the inuence of surface
nishing on the tribological behaviour of coatings. Grinding
is normally adopted for nishing operations of hard coating
materials [9,10].
However, the effect of grinding on the performance of the
coating is rarely investigated. It was the aim of this work
to study the effect of grinding on the erosion behaviour of
WCCoCr coating deposited by two high velocity coating
processes namely, HVOF and DS processes.
2. Experimental
2.1. Material
WCCoCr (Sulzer Metco 5847) was used as the coating
powder. A medium carbon steel equivalent to AISI4043 was
used as the substrate material. Table 1 gives the coating ma-
terial characteristics as provided by the manufacturer. The
erosion test coupons of dimensions 30 mm30 mm5 mm
thick were prepared by machining prior to coating. The test
coupons were grit blasted with Al
2
O
3
grits of 46 mesh at
2.5 bar and cleaned with carbon tetrachloride. Two high ve-
locity thermal spray processes namely HVOF and pulse DS
were used to deposit the above coating powder onto the
grit blasted steel substrate to a thickness of approximately
400 m. The spraying conditions were optimised in order to
get higher hardness and lower porosity. The spraying con-
ditions adopted in the present work are given in Table 2.
2.2. Grinding conditions
To study the effect of grinding on the erosion performance,
some of the HVOF and the DS coated samples were ground
Table 1
Coating powder characteristics
WCCoCr (SM 5847)
Composition 10 wt.% Co
4 wt.% Cr
86 wt.% WC
Particle size (53 + 11) m
Shape Mostly spherical
Manufacturing route Agglomerated/sintered
Table 2
Spraying conditions adopted for HVOF and DS processes
HVOF process
Spray Gun DJ2600
O
2
pressure (MPa), ow rate (m
3
/h) 1.1, 1.8
H
2
pressure (MPa), ow rate (m
3
/h) 0.9, 3.6
Air pressure (MPa), ow rate (m
3
/h) 0.66, 1.2
Spray rate (kg/h) 34
Carrier gas Nitrogen
Spraying distance (m) 0.2
Detonation gun spray (DS) process
O
2
/acetylene volume ratio 1:1.23
Carrier gas ow rate (m
3
/h) 1.6
Spray distance (m) 0.165
Frequency of shots (shots/s) 3
with a diamond resin bonded wheel under the conditions
given in Table 3 to achieve a nal surface roughness of R
a
<
0.2 m.
2.3. Characterisation
Following characterisations have been carried out for
coatings as a part of the present work.
1. X-ray diffraction (XRD) analysis of the powder, coating
in as-sprayed condition and the coating in as-ground con-
dition. A Phillips PW1320 diffractometer with Cu K
radiation operated at 40 kV and 25 mA was employed for
this purpose.
2. Surface roughness measurements on the coating in
as-sprayed condition and the coating in as-ground con-
dition using a Surftest surface roughness tester.
3. Residual stress measurements using American stress
measuring technologies (Model X2002). X-ray diffrac-
tion technique was used for residual stress measurements
on the coated samples before and after grinding. X-ray
diffraction was done by peak shift sin
2
technique
[11] using Cr K radiation (wave length 2.2910 ).
The Bragg reection (from WC) used for the mea-
surement was from the (256) plane. The measurements
were carried out at a tube voltage of 30 kV, current of
6 mA and collimator diameter of 5 mm. The Youngs
modulus value of 180 GPa was used in estimating the
residual stress for both HVOF and DS coatings. This is
based on the modulus values provided in [12] for HVOF
Table 3
Grinding conditions
Wheel speed (ms
1
) 25
Table speed (ms
1
) 6
Infeed per pass (m)
Rough grinding 10
Finishing 5
Cross-speed (mm per pass) 0.75
Lubricant Water soluble oil
594 J.K.N. Murthy et al. / Wear 249 (2001) 592600
coated WC(17%)Co estimated by cantilever beam
method.
4. Other characterisations involved scanning electron mi-
croscopy (SEM); using a Jeol make SEM, microhardness
measurements; using Leitz microhardness tester with
Vickers indenter at a load of 300 g and porosity mea-
surements using Leitz microscope tted with a Q-520
image analyser, on the sectioned and polished surface of
the transverse section of the coating.
2.4. Erosion tests
An air jet erosion tester, a schematic view of which is
shown in Fig. 1, was used for erosion testing of the sub-
strate and as-sprayed HVOF and DS coated samples. Silica
particles used as the erodent were fed by a particle feeder
at a controlled rate into the mixing chamber where they en-
trained the dry high velocity air coming from the compres-
sor. The particles further accelerated as they moved with
the air stream through a tungsten carbide converging noz-
zle and then nally hit the sample kept xed on the sample
holder. The velocity of the impinging particles were mea-
sured using the well known double-disc method. The im-
pact angle was varied by simply varying the orientation of
the sample surface with respect to the impinging particles
stream. The erosion test conditions utilised in the present
study are listed in Table 4. The erosion test was carried out
as follows. The sample was rst cleaned in acetone using
an ultrasonic cleaner, dried and then weighed using an elec-
tronic balance having a resolution of 0.01 mg. The sample
was next xed to the sample holder of the erosion rig and
eroded with silica particles at the predetermined particle feed
rate, impact velocity and impact angle for a period of about
5 min. The sample was then removed, cleaned in acetone
Fig. 1. Schematic diagram of the solid particle erosion test rig.
Table 4
Erosion conditions
Erodent material Silica
Particle size (m) 106150
Particle shape Angular
Particle velocity (m/s) 80
Feed rate (g/min) 4.3
Nozzle distance (mm) 10
Impact angles (

) 90, 30
and dried and weighed to determine the weight loss. This
weight loss normalised by the mass of the silica particles
causing the weight loss was then dened as the incremen-
tal erosion rate. The above procedure was repeated till the
incremental erosion rate attained a constant value indepen-
dent of the mass of the erodent particles or, equivalently, of
testing time. This constant value of the incremental erosion
rate was dened as the steady-state erosion rate. The incre-
mental erosion rate was converted into volume wear rate to
take into account the different densities of the coating mate-
rial and the substrate. The densities adopted for the coating
and the substrate were 12500 kg/m
3
and 7800 kg/m
3
, respec-
tively. The ground samples were erosion tested under simi-
lar conditions as followed for as-sprayed coatings. The di-
rection of particle impact on the ground sample for oblique
impact was normal to the grinding direction (i.e. across the
lay).
3. Results and discussion
3.1. X-ray diffraction analysis
Fig. 2a shows the XRD pattern for the WCCoCr pow-
der. Fig. 2b and c show XRD patterns for both HVOF and
DS coatings, respectively, in the as-sprayed condition. WC
was the major phase in both the coating processes while
W
2
C phase was also observed indicating that partial decar-
burisation of WC has taken place during the coating pro-
cess. The metallic tungsten which is found in WCCo coat-
ing [3] is not detectable in WCCoCr coating. According
to Karimi et al. [3] chromium addition to WCCo inhibits
the decarburisation of WC to metallic tungsten. Although
notable quantity of binder phase is present in the coating,
it is not detectable, possibly because the binder phase is in
the form of nanocrystalline and/or amorphous phase as has
been reported [3]. Karimi et al. further observed that Cr
addition to cobalt binder enhances the binding of carbide
grains. Fig. 2d and e show the XRD patterns of the coat-
ing for both HVOF and DS processes after grinding which
are quite similar to the XRD patterns obtained for the coat-
ing prior to grinding. This suggests that grinding did not
result in any phase transformations in the coating. It is not
surprising as local heating was minimised by using suit-
able coolant in ood cooling condition during the grinding
process.
J.K.N. Murthy et al. / Wear 249 (2001) 592600 595
Fig. 2. XRD patterns (a) WC10Co4Cr powder; (b) and (c) HVOF and DS coatings, respectively, in as-sprayed condition; (d) and (e) HVOF and DS
coatings, respectively, in as-ground condition.
3.2. Microstructure, surface roughness and residual
stress characteristics
Fig. 3 shows the microstructure of WCCoCr powder.
The particles were mostly spherical with some having elon-
gated shape. Fig. 4a and b show the microstructures of the
transverse section of the HVOF and DS coated samples in
the as-sprayed condition prior to grinding. The DS coated
sample resulted in slightly denser coating. Table 5 shows the
percentage porosity and microhardness values of the coating
for the two coating processes. The microhardness in the case
of DS was found to be slightly higher. Very high kinetic en-
ergies involved in the HVOF and DS processes help in at-
tening the particle upon impact and provide improved adhe-
sion to the substrate and lower porosity in the coating [13].
Among the HVOF and DS processes, the latter is known to
596 J.K.N. Murthy et al. / Wear 249 (2001) 592600
Fig. 3. SEM micrograph of WC10Co4Cr powder.
Table 5
Coating characteristics of as-sprayed coating
WCCoCr
HVOF DS
Microhardness (HV
0.3
) 792 849
Porosity (%) 1.6 1.3
Average surface roughness, R
a
(mm) 3.93 4.05
have higher particle velocities compared to the former. Fur-
ther, the particle temperature is marginally higher (thus the
lower strength material being more amenable to attening
upon impact) in the DS process as compared to the HVOF
process. Hence, the DS coating is expected to give slightly
higher microhardness value and also lower porosity. The
Table 5 also shows the average surface roughness of the
coating in the as-sprayed condition. The surface rough-
ness was higher in the DS coating. The morphology of the
ground surface is shown in Fig. 5a and b for HVOF and
DS coatings, respectively. It shows the grinding induced
surface damage in both the cases. Fig. 6a and b show the
microstructures of the transverse sections of the coating in
the ground condition for HVOF and DS samples, respec-
tively. It can be noted that the microstructure of the HVOF
Fig. 4. SEM micrographs of transverse section of WC10Co4Cr coating in as-sprayed condition: (a) HVOF coating; (b) DS coating.
coating developed numerous cracks beneath the surface
up to a depth of 150200 m. However, such cracks were
minimum in the case of DS samples (Fig. 6b).
The residual stress measurement of the WCCoCr coat-
ing was carried out using the X-ray diffraction technique.
Table 6 shows residual stress values. In the as-sprayed con-
dition, the coating was found to have compressive stresses
which possibly occurred due to the differential thermal con-
traction between the coating and the substrate during the
powder deposition process [14]. In fact, the residual com-
pressive stress in the detonation gun coating was found to
be much higher than that for the HVOF coating. The resid-
ual stress measurements were also carried out on the ground
coated samples. It was found that grinding in general re-
sulted in higher residual compressive stresses as compared
to their as-sprayed counterpart in the case of both HVOF
and DS samples. Given the fact that coolant was used while
grinding, the heat generation at the surface was minimal,
the compressive residual stress was possibly as a result of
the mechanical interaction of abrasive grains with the work
piece leading to non-uniform plastic deformation which in-
duced compressive residual stresses [15]. The super imposed
hydrostatic compressive stress present during the grinding
process in the depth direction of the specimen below the
grinding wheel is responsible for high compressive residual
stress below the ground surface. The stress measurement in
the direction normal to and along the grinding direction on
the samples further revealed that the compressive stress nor-
mal to the grinding direction (across the lay) was higher than
that along the lay. Such anisotropic trend in compressive
residual stress has been earlier observed in bulk Si
3
N
4
spec-
imens after grinding [16]. Even after grinding, the DS sam-
ples were found to have higher residual compressive stress
than that of the HVOF coated samples as shown in Table 6.
3.3. Erosion behaviour of as-sprayed samples
The steady-state volume erosion rate of the substrate along
with that of coating are shown in Fig. 7 at both 90

and
30

impact angles. It clearly shows that the erosion rate

J.K.N. Murthy et al. / Wear 249 (2001) 592600 597
Fig. 5. SEM micrographs showing the surface morphology of WC10Co4Cr coating after grinding: (a) HVOF coating; (b) DS coating.
Fig. 6. SEM micrographs of transverse section of WC10Co4Cr coating in as-ground condition: (a) HVOF coating; (b) DS coating.
at 30

impact is higher than that at 90

for the steel sub-

strate which is common for ductile materials [17] where
material removal takes place predominantly by plastic de-
formation. The Fig. 7 also shows the volume wear rate
for WCCoCr coating which reveals that the erosion rate
at 90

impact angle was higher than that at 30

which is
the characteristic erosion behaviour of brittle materials [17].
This is also expected as the WCCoCr material is known
to have brittle type of erosion behaviour where material
removal takes place predominantly by carbide particle frac-
ture and fracture involving crack initiation at particle-matrix
Table 6
Residual stress for the WCCoCr coating before and after grinding
Residual stress (MPa)
Longitudinal Transverse
HVOF
As-sprayed 25.9 23.3
Ground 71.6 125.1
DS coating
As-sprayed 104
Ground 233.9 252.4
interface and its propagation to the free surface. The extent
of cracking is most severe when the impact direction is nor-
mal to the surface leading to higher erosion rate. In as-coated
form, the erosion rate at both the impact angles were higher
in the case of HVOF coating as compared to DS coating. In
brittle materials, higher porosity is also known to result in
higher erosion rate. Given the fact that HVOF coatings have
marginally higher porosity and lower residual compressive
stresses as compared to DS coatings as given in Tables 5
and 6, higher erosion rate in HVOF coating compared to DS
coating might be expected.
3.4. Effect of grinding on the erosion behaviour
As mentioned earlier, grinding is normally adopted for
nishing of carbide coatings. Therefore, inuence of grind-
ing on the tribological properties needs to be understood.
In the literature, this aspect has not been addressed so far.
However, effect of grinding on monolithic ceramic material
has been reported by Srinivasan et al. [16]. Thus, the present
study represents one of the rst to report on the effect of
grinding on the tribological behaviour of thermally sprayed
coatings.
598 J.K.N. Murthy et al. / Wear 249 (2001) 592600
Fig. 7. Steady-state volume erosion rate.
Fig. 8. SEM micrographs showing the eroded surface morphology of WC10Co4Cr coating by HVOF process. (a) and (b) As-sprayed and as-ground
condition, respectively, at normal impact; (c) and (d) as-sprayed and as-ground condition, respectively, at 30

impact. The erodent particle ow direction

is indicated by the arrow mark.
J.K.N. Murthy et al. / Wear 249 (2001) 592600 599
The improvement in erosion resistance as a result of grind-
ing in the case of HVOF coating and DS coating is quite
signicant as shown in Fig. 7. Fig. 8 shows the SEM mi-
crographs of the surface morphology of the eroded surface
of coatings deposited by HVOF process. Fig. 8a and b are
the eroded surface of as-coated and as-ground samples,
respectively, tested at normal impact. Fig. 8c and d are the
eroded surface morphology of as-coated and as-ground
specimens tested at 30

impact angle.
It is clearly noticed in Fig. 8a that in as-coated condi-
tion tested at normal impact, the eroded surface consists of
numerous craters formed by erodent particle impact. The
craters that are larger in diameter consisted of characteristics
of particle pull out induced voids and gross spalling of the
coating. In some regions the pull out areas are surrounded
by lip suggesting strain localisation which is a common fea-
ture in ductile erosion mode. Such ductile erosion is possibly
on the CoCr metallic binder phase. Otherwise, the erosion
involved material removal by spalling of coating dominated
by fracture of carbide particles and their pull out from the
binder phase. Thus, the erosion is predominantly brittle in
nature. The grinding has changed the erosion morphology
signicantly. As shown in Fig. 8b, the as-ground speci-
mens tested at normal impact contained craters which are
smaller in size as compared to that in as-coated specimens.
Thus, the grinding has resulted in reduction in erosion rate
at normal impact. At oblique impact also, similar trend is
observed. For example, the as-coated specimens tested at
30

impact angle consisted of deeper grooves along the par-

ticle impact direction as a result of ploughing of erodent par-
ticles on the coating. In the ground specimen tested at 30

,
the width and depth of the grooves were much smaller as
compared to the grooves in as-coated condition suggesting
lower penetration in the as-ground specimens. Fig. 8c and d
also indicate particle pull out along the grooves. The damage
due to particle pull out was much larger in the as-coated
(Fig. 8c) condition than in the as-ground condition.
As mentioned earlier, surface grinding on HVOF and DS
coatings resulted in compressive residual stress as shown
in Table 6. In tungsten carbide based material, it is known
that the erosion rate is governed by brittle erosion mecha-
nisms dominated by particle fracture and fracture involving
crack nucleation and propagation at the particle-matrix in-
terface. In brittle materials, the compressive residual stress
is known to mitigate impact wear damage as reported by
Srinivasan et al. [16] in the case of monolithic Si
3
N
4
as it is
known to impede crack initiation and propagation [18,19].
Therefore, the fracture of carbide grains and fracture at the
particle-matrix interface has been signicantly reduced by
the higher compressive residual stress in the as-ground
specimens leading to lower volume wear rate. When com-
paring the compressive residual stress in as-ground HVOF
coating with that of DS coating (Table 6), DS coating re-
sulted in higher compressive stress. However, the erosion
rate (Fig. 7) at normal impact in as-ground specimens is
found to be nearly same for these two coatings. This could
be attributed to the following. The volume wear rates shown
in Fig. 7 were estimated assuming a constant density value
for both HVOF and DS coatings. However, the actual den-
sity values will differ based on the porosity and microc-
racks in the coating. Given the fact that HVOF specimens
in as-ground condition contained higher density of cracks
(Fig. 6a) as compared to DS coatings (Fig. 6b), the ac-
tual density of as-ground HVOF coating is expected to be
relatively lower as compared to the density of as-ground
DS coating. Therefore, the relative volume wear rate for
as-ground HVOF specimens would be higher even under
normal impact as compared to as-ground DS coating if the
actual density of the coating is taken into account.
Compared to HVOF coating, DS coating has shown more
improvement in erosion resistance at 30

impact angle af-

ter grinding as shown in Fig. 7. The severity of fracture is
less intense at oblique impact, and also higher compressive
residual stresses impede crack nucleation and propagation.
It is to be noted that in case of HVOF coating, grinding also
induced cracks that are parallel to the ground surface. These
cracks will reduce the erosion resistance at oblique impact
as these cracks cannot offer resistance to shear force present
during impacting of particles at oblique angle resulting in
higher erosion.
To conclude, this study shows that nishing operation
inuences the coating characteristics and its performance,
and the grinding improves the erosion resistance of the
WCCoCr coated by HVOF and DS processes. Improve-
ment in erosion resistance may possibly be due to an in-
crease in compressive residual stresses.
4. Conclusions
1. In as-coated condition the microhardness of the
WCCoCr coating coated by detonation gun spray
process is slightly higher than that coated by HVOF
process. This is possibly due to slightly higher density
in DS coating.
2. The erosion resistance of the DS coating was found to
be higher compared to that of the HVOF coating in the
as-coated condition. This is possibly due to the slightly
higher microhardness, lower porosity and possibly higher
residual compressive stresses of the DS coating.
3. The erosion resistance of the coating after grinding was
found to be higher than that in the as-coated condition
possibly due to the higher compressive residual stress
induced during grinding which impedes particle fracture
and in turn resulting in lower erosion rate.
Acknowledgements
The help provided by Dr. K.M. Reddy in the residual
stress measurement is acknowledged. The assistance by Mr.
G.V.K. Reddy and Mr. John David in the SEM investiga-
600 J.K.N. Murthy et al. / Wear 249 (2001) 592600
tion is gratefully acknowledged. The authors are thankful
to the Director, DMRL for granting permission to publish
this paper. Mr. Dimanth Doshis help in HVOF coating also
deserves acknowledgment.
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