Abstract Material and spray process selection are the key factors in the tailoring of thermal sprayed coatings for demanding industrial applications. In this study, four commercial Cr3C2-based feedstock materials were sprayed with gas-fuelled high-velocity oxygen-fuel (HVOF) and modern high-velocity air-fuel (HVAF) spray processes. Two materials with standard Cr3C2–25NiCr composition (porous and dense), a Cr3C2–50NiCrMoNb and Cr3C2–37WC–18NiCoCr materials were sprayed in addition to the reference WC-10Co4Cr material. The Cr3C2–50NiCrMoNb had a higher content of the Ni-based metal matrix compared to standard Cr3C2–25NiCr composition for added corrosion resistance, while the Cr3C2–37WC–18NiCoCr material contained additional tungsten carbide (WC) particles to improve the wear resistance. In abrasion and dry particle erosion, the Cr3C2–50NiCrMoNb coatings showed a higher degree of plastic deformation and increased material loss, whereas the Cr3C2–37WC–18NiCoCr coating had wear resistance between the standard Cr3C2–25NiCr and reference WC-10Co4Cr coatings. In cavitation erosion, the lower carbide content of Cr3C2–50NiCrMoNb coatings turned out to improve the resistance against fatigue wear due to higher fracture toughness. Overall, the HVAF sprayed coatings had higher elastic modulus, higher fracture toughness, equal or higher abrasion and erosion resistance, and higher cavitation erosion resistance compared to the HVOF sprayed counterparts.

中文翻译：

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Cr3C2 基 HVOF 和 HVAF 喷涂涂层的研究：磨损、干颗粒侵蚀和抗空蚀性

摘要 材料和喷涂工艺的选择是为要求苛刻的工业应用定制热喷涂涂层的关键因素。在这项研究中，四种商用 Cr3C2 基原料材料采用气体燃料高速氧气燃料 (HVOF) 和现代高速空气燃料 (HVAF) 喷涂工艺进行喷涂。除了参考 WC-10Co4Cr 材料外，还喷涂了两种具有标准 Cr3C2-25NiCr 成分（多孔和致密）的材料，即 Cr3C2-50NiCrMoNb 和 Cr3C2-37WC-18NiCoCr 材料。与标准 Cr3C2-25NiCr 成分相比，Cr3C2-50NiCrMoNb 具有更高含量的 Ni 基金属基体，以提高耐腐蚀性，而 Cr3C2-37WC-18NiCoCr 材料包含额外的碳化钨 (WC) 颗粒以提高耐磨性。在磨损和干颗粒侵蚀中，Cr3C2-50NiCrMoNb 涂层表现出更高程度的塑性变形和增加的材料损失，而 Cr3C2-37WC-18NiCoCr 涂层的耐磨性介于标准 Cr3C2-25NiCr 和参考 WC-10Co4Cr 涂层之间。在空蚀中，Cr3C2-50NiCrMoNb 涂层的较低碳化物含量由于较高的断裂韧性而提高了抗疲劳磨损能力。总体而言，与 HVOF 喷涂涂层相比，HVAF 喷涂涂层具有更高的弹性模量、更高的断裂韧性、相等或更高的耐磨性和抗侵蚀性以及更高的抗气蚀性。由于较高的断裂韧性，Cr3C2-50NiCrMoNb 涂层的较低碳化物含量被证明提高了抗疲劳磨损能力。总体而言，与 HVOF 喷涂涂层相比，HVAF 喷涂涂层具有更高的弹性模量、更高的断裂韧性、相等或更高的耐磨性和抗侵蚀性以及更高的抗气蚀性。由于较高的断裂韧性，Cr3C2-50NiCrMoNb 涂层的较低碳化物含量被证明提高了抗疲劳磨损能力。总体而言，与 HVOF 喷涂涂层相比，HVAF 喷涂涂层具有更高的弹性模量、更高的断裂韧性、相等或更高的耐磨性和抗侵蚀性以及更高的抗气蚀性。