Influence of different rare earth oxides on CNC ultrasonic machining of HP-HVOLF sprayed ceramics coating

The current study aimed at the optimization of process parameters for microchannel fabrication on thermal sprayed carbide coatings using rotary ultrasonic machining (RUSM). Rare earth oxides (REOs) such as La₂O₃, CeO₂, and Er₂O₃ have been incorporated into WC-Co-Cr coatings to enhance machinability and improve coating characteristics. The research has demonstrated that La₂O₃ doped coatings have significantly increased the material removal rate (MRR), with a 15 % improvement when compared to undoped coatings. Additionally, surface roughness has been reduced by 20 %, resulting in a smoother and more uniform finish. The inclusion of REOs has refined the microstructure of the coatings, yielding denser and more compact layers, which has reduced defects and improved the overall surface quality. Furthermore, the hardness of the coatings has been enhanced by 45 %, with La₂O₃ doped coatings achieving a maximum hardness value of 1313 ± 11 HV. The findings have highlighted the potential of REO doping to enhance the performance and efficiency of microchannel fabrication on WC-Co-Cr coatings using RUSM, contributing valuable insights to industrial applications.