Slurry Erosion Behavior of Ni-Al and Fe-Cr Coatings Deposited by Arc Wire Spray on Hydro Machinery SS316 Steel

This research delves into the slurry erosion behavior of Ni-Al and Fe-Cr coatings, applied using arc wire spraying (AWS) on hydro machinery SS316 steel. The surface and cross-section microstructures were analyzed using backscattered-scanning electron microscopy, Vickers microhardness, porosity percentage, and surface roughness testing, and bonding strength. Furthermore, slurry erosion tests were also performed to evaluate the mass loss for the coated and uncoated samples. Subsequent slurry erosion testing, under diverse parameters, unveiled the exceptional erosion resistance of Ni-Al coatings across varying jet velocities, slurry concentrations, and impingement angles. Moreover, analysis of the eroded surface was done with the assistance of FESEM images to evaluate the type and severity of the erosion. The analysis of erosion mechanisms, such as ploughing, cratering, micro-cutting, ductile failure, delamination, and roughened surfaces, provides nuanced insights into coatings responses to abrasive slurry particles.