Journal of Materials Processing Technology 152 (2004) 43–55

Alternative to chromium: characteristics and wear behavior of HVOF

coatings for gas turbine shafts repair (heavy-duty)
Tahar Sahraoui∗ , Nour-Eddine Fenineche, Ghislain Montavon, Christian Coddet
Universite de Technologie de Belfort-Montbeliard, LERMPS, Site de Sevenans, Belfort 90010, France
Received 12 February 2003; received in revised form 27 January 2004; accepted 2 February 2004

Abstract

Hard chromium plating is usually used to restore to original dimensions the worn surfaces of gas turbine shafts. However, such a
technology presents harmful effects on the environment and the public health and it exhibits, moreover some intrinsic technical limitations.
HVOF (high-velocity oxy-fuel) thermal spraying process appears as more environmentally friendly than chromium plating process but
exhibits also lower potential production costs when compared to hard chromium deposits.
In such a way, HVOF process appears as an alternative to hard chromium plating for shafts repair, by reducing the frequency of
maintenance operation and repair and by deferring the need to fabricate or to buy replacement parts for used engines of previous generation.
The purpose of this study was to investigate and to compare microstructural properties, wear resistance, and potentials of HVOF sprayed
Tribaloy©-400 (T-400), Cr3 C2 –25%NiCr and WC–12%Co coatings for a possible replacement of hard chromium plating in gas turbine
shafts repair. It was shown that thermal spray coatings exhibit the adequate properties compared to electrodeposited hard chromium
coatings.
© 2004 Elsevier B.V. All rights reserved.

Keywords: Coating; Carbides; Hard chromium; Coefficient of friction; Wear; Repair

1. Introduction level (PEL)1 of the operators to hexavalent chromium is to-

The most severe degradation modes that gas turbine
shafts have to face are friction and wear. Surface damages
generated by the sliding contact with bearings limit the
life of the shafts and therefore reduce their durability and
reliability [1]. Hard chromium plating is usually used to re-
store the original dimensions of worn surfaces of the shafts,
pumps and compressors [2–4]. However, during the last
decade, there has been an increasing concern surrounding
the processing of chromium coatings using electroplating.
This is due to environmental, health and safety consider-
ations associated with the handling, storage, and disposal
of hexavalent chromium (Cr6+ ) compounds normally used
during the plating process [5–9].
Chromium ions reduced in the electrolytic process are
in hexavalent state (Cr6+ ), known to show an exacerbated
carcinogenic character, among other developed pathologies.
These very harmful effects, like nasal perforation have been
reported since 1827 [10]. Thus, the daily average exposure
∗ Corresponding author. Tel.: +33-384-58-30-23;
day relatively low, and the new standards to come, in par-
ticular in the United States, but also in Europe, will be even
more drastic. From a current PEL reactulized in 1996 of
0.1 mg m−3 , the new standards would recommend a PEL of
0.0005 mg m−3 [11].
The effects of rejections of chromium and of rinsing ef-
fluents on the acidification, as well as on the entrophication
of the grounds and waters, are particularly disastrous. This
is why the environmental standards, already more strictly
reinforced than a few years ago, will also become even
more severe in a near future. Currently, and since 1999, the
maximum limit of chromium discharge in water amounts
to 2.77 ml per day and to 1.71 ml per day on average per
month. The recommendations of the new standards would
amount to 0.3 ml per day and to 0.2 ml per day for the daily
maximum rejections and the daily average rejections per
month, respectively. Moreover, the low wettability of hard
chromium by water based media and oil leads also some-
times to problems related to lubricant adhesion during slid-
ing friction conditions [12].

fax: +33-384-58-32-86. 1 Permissible exposure limit, daily average concentration level (8 h per

E-mail address: tahar.sahraoui@utbm.fr (T. Sahraoui). day and 40 h per week) that must not be exceeded.

0924-0136/$ – see front matter © 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2004.02.061
44 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55

Table 1
Sale turnovers comparison for various surface treatment techniques
Processes 1990 (M ) 2000 (M ) 2010a (M )

Thermal spray process 300 400 500

Physical vapor deposition process 100 180 250
Chemical and electroplating processes (“hard chromium” mainly) 400 400 400
Data for years 1990 and 2000 and perspectives for year 2010 for the European Economic Community (EEC) [22].
a Estimations.

Table 2
Comparison of coating manufacturing costs for thermal spraying and for hard chromium plating in the case of a component simulating a small hydraulic
ram of 50 mm diameter and 500 mm length [2,23]
Materials Tungsten carbide Nickel chrome boron Hard chromium plating
10%Co–4%Cr ( ) silicon hardfacing (power + direct labor
alloy ( ) + chemical + misc
+ waste treatment) ( )
Raw material cost (powder) ∼30 ∼7
Energy cost (oxygen and kerosene) ∼7 ∼7
Labor cost for surface preparation, ∼13 ∼13
spraying and component handling
(20 min)
Total coating cost ∼50 ∼27 ∼270

Various processes offer themselves as alternatives to
chromium plating: i.e., trivalent chromium plating, physi-
cal vapor deposition (PVD), and thermal spraying, among
others.
Trivalent chromium process permits to obtain deposits
of hardness, abrasion resistance and friction coefficient
equivalent to those resulting from hexavalent solutions,
but the behavior in regards with corrosion remains very
poor [13]. Coatings manufactured implementing physical
vapor deposition process exhibit very high hardness (i.e.,
2000–3000 HV) [14] and permit the improvement of the
wear and friction properties [12]. However, the performance
of these coatings remains in some cases limited because of
their low thickness (1–10 ␮m), their moderate load capacity
and their abrupt interface [15]. Coatings deposited by ther-
mal spraying appear also as alternatives to hard chromium
plating [16], in spite of the realization of the parts in a
unit way, of the limitations in minimum dimensions of the
parts to be coated, and of the limitations in the minimum
internal diameter of the cylinder that can be coated (i.e.,
Φmini = 40–80 mm) [17].
Faced with this combination of difficulties and limits
found in these processes, both environment-friendly and
more flexible coatings implementing thermal spraying pro-
cess have been used for a few years, providing a better
productability. It should be noted that the sales turnovers
relating to thermal spraying process know a remarkable
increase, Table 1 [18,19]. The emergence and the develop-
ment of the high-velocity oxy-fuel (HVOF) thermal spray-
ing process over the last decade has enabled the production
of very dense metallic and cermets coatings, offering an
effective substitute for hard chromium plating for certain
jet engine components, among other components. [20–24].
With HVOF systems, the feedstock material is heated to
near or above its melting point by a high-velocity combus-
tion gas stream (resulting from continuous combustion of
fuels including propane, propylene, methane or hydrogen)
and deposited [23,24].
The parts actually repaired by hard chromium plating con-
sidered in this work are shafts of THM2 1102, 1202, and
1203 gas turbine engines. It has been noted that shaft repair
using hard chromium plating process requires a long period
of standstill [2], and the manufacturing costs are very high
(up to five times, in a first approximation) compared to those
of thermal spraying process [2,25], Table 2.
The present study was undertaken to investigate the poten-
tial of WC–12%Co, Cr3 C2 –25%NiCr, and Tribaloy©-400
coatings manufactured by HVOF spraying to replace elec-
trodeposited chromium. The targeted applications involve
those in which the coated surfaces could be exposed to
friction and wear, like sliding bearings of the shafts of the
compressor rotor, Fig. 1.
2. Materials and experiments
2.1. Coating manufacturing
Experiments involved the manufacturing and characteri-
zation of coatings deposited by HVOF spraying or by elec-
trodeposition and the quantification of their friction and wear
behaviors.
2 MAN Turbomaschinen AG, GHH BORSIG, Steinbrinkstrasse 1, Ober-
hausen, Germany.
 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55 45

Fig. 1. THM gas turbine shafts: (a) worn surfaces; (b) hard chromium electrodeposition on shafts (bearings).

The considered feedstocks were WC–12%Co (Amdry3 Table 3

1301), Cr3 C2 –25%NiCr (Amdry 5260) and Tribaloy©-400 Chemical composition of powders: (a) Amdrya 19155 (Tribaloy©-400),
(Amdry 19155) powders for thermal spray coatings. Table 3 (b) Amdrya 5260 (Cr3 C2 –25%NiCr) and (c) Amdrya 1301 (WC–12%Co)
presents the chemical composition and the manufacturing (production method: agglomerated and sintered)
method of the powders. Element wt.%
The three feedstocks exhibit a particle size distribution (a) Amdrya 19155
ranging from 11 to 45 ␮m. Fig. 2 shows their spherical mor- Co Balance
phology. Cr 8.50
Spray coatings were manufactured implementing thermal Mo 28.69
spraying by supersonic flame. The spraying equipment used Si 2.46
Ni <0.50
was a commercial Sulzer-Metco CDS system operating with Fe <0.25
methane and oxygen as combustion gases and using a bar- P <0.03
rel of three in length. The 250–350 ␮m thick coatings were S <0.03
deposited onto AFNOR 25CD4 low carbon steel samples, (b) Amdrya 5260
Table 4. The HVOF spray parameters are given in Table 5. C 9.23
Hard chromium coatings were realized in a private company Cr Balance
specialized in this field following the state of the art in- Ni 19.6
dustrial standards. The same substrate nature, i.e., AFNOR (c) Amdrya 1301
25CD4, was considered and hard chromium coatings were Co 11.4
about 350 ␮m thick. WC Balance
C (free) <0.20
Fe <2.0
3 a Sulzer-Metco AG, Rigackerstrasse 16, S160 Wohlen, Switzerland.
Sulzer-Metco AG, Rigackerstrasse 16, 5160 Wohlen, Switzerland.
46 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55

Table 4
AFNOR 25CD4 steel composition (wt.%)
C 0.25
Si 0.25
Mn 0.70
Cr 1.05
Mo 0.25
Fe Balance

Table 5
High-velocity flame spraying conditions
Oxygen flow rate (SLPM) 420
Powder carrier gas (SLPM) 20
Fuel gas (methane) (SLPM) 180
Nozzle (in.) 3
Spray distance (mm) 300

Table 6
Mean chemical composition of the brass used in this study as counter
samples
Cu Balance
Pb 1.9
Ni 1
Zn 8.1

After metallographic preparation consisting in sample

cutting using an abrasive saw, in sample mounting in epoxy
rings and in pre-polishing and polishing using diamond
slurries on an automatic polishing system to enhance re-
producibility, coatings were observed and image analysis
was implemented to determine the coating porosity level.
Coating upper surface roughnesses were measured using
a mechanical stylus. Average roughness (Ra ) and mean
square roughness (RMS) [26] were determined 10 times
on three different samples of each nature and the results
were averaged. Vickers hardness values were determined
on coating polished cross-sections under a load of 0.3 kg
(i.e., HV0.3 kgf ). Six measurements were performed on three
different samples of each nature and the results were also
averaged.

2.3. Coating friction and wear behavior

characterization

Friction and wear tests were performed on the one hand

Fig. 2. Initial feedstock powder morphology: (a) T-400; (b) Cr3 C2 –
25%NiCr; (c) WC–12%Co.
2.2. Coating structural characterization
For microstructural analyses and worn surfaces observa-
tion, scanning electron microscopy (SEM), energy disper-
sive spectroscopy (EDS) and X-ray diffraction (Cu K␣ ra-
using a pin-on-disc (POD) arrangement on a CSEM4 tri-
bometer, and on the other hand using an Amsler machine.
The POD test is a model test for determining friction
characteristic and wear behavior of two solid surfaces being
in sliding contact, Fig. 3. The pins were coated and slided
against a disc made of brass (C31600), Table 6. This mate-
rial is very often used for sliding bearing purposes, among
other materials [27], and was selected to perform friction
4 Centre Suisse d’Electronique et de Microtechnique SA, Jaquet Droz

diation; i.e., 1.54 Å wavelength) were used. 1, 2007 Neuchâtel, Switzerland.

 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55
Fig. 3. Pin-on-disc tribometer implemented in this study.
and wear tests in more severe conditions compared to other
materials, such as babbitts, for example. The selected nor-
mal loads applied to the pin were 5, 10 and 20 N. As a re-
sult of rotational speed and radius of the sliding path, the
selected relative velocities between pins and surfaces were
0.14, 0.70 and 0.84 m s−1 .
Fig. 4. Amsler specimen geometry.
47
The Amsler tribometer permits to determine the wear of
materials by friction. Fig. 4 shows schematically the experi-
mental configuration. The coated discs were sliding against
discs made of the same brass material than the one used
for the POD experiments. The forces with which the sam-
ples were pressed together during the tests were 245, 490
and 735 N. The radial velocities were 0.52 m s−1 for the
coated samples (down disc) and 0.47 m s−1 for the brass
discs (upper disc), inducing a sliding between the discs
of 10%.
In order to study the tribological behavior of coatings in
severe conditions, the tests were carried out without any
lubrication. The wears experienced by the samples during
the tests were determined in terms of mass, by weighting
each sample before and after the test, and also in terms of
samples dimension evolution, by measuring the diameter of
each Amsler disc and the length of each pin before and af-
ter the tests. Prior to the friction and wear tests, the coat-
ings were ground, and the counter samples surfaces were
polished.
3. Results and discussion
3.1. Coatings structural characterization
3.1.1. Tribaloy©-400
The Tribaloy©-400 is primarily made of cobalt and
molybdenum. Fig. 5 illustrates the X-ray diffraction pat-
terns of the feedstock powder and the as-sprayed coat-
ing, respectively. The coating exhibits crystallized phases
which consist primarily in cobalt (cubic) solid solution
and Co3 Mo2 Si laves phase. Regarding the peak intensi-
ties and their broadening, the authors assume also that
48 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55

Table 7
Coatings characteristics
Deposits Average roughness Average roughness Porosity level Average micro-hardness
(as-deposited), Ra (␮m)a (grinded), Ra (␮m)a (%) (HV0.3 kgf )b
Tribaloy©-400 6.87 ± 0.23 1.20 ± 0.19 0.41 703 ± 72
Cr3 C2 –25%NiCr 8.38 ± 0.61 0.64 ± 0.09 1.47 854 ± 93
WC–12%Co 7.98 ± 0.36 0.61 ± 0.07 0.38 1253 ± 176
Hard chromium plating 1.94 ± 0.42 0.42 ± 0.06 1.52 783 ± 51
a Average value ± standard deviation from 10 data points.
b Average value ± standard deviation from six data points.

there is a mixture of amorphous and extremely fine
crystalline phases (nanocrystallines). These results agree
with those obtained by Xiao-Xi and Zhang for HVOF
sprayed Tribaloy©-800 [28]. The cross-sectional view of
the as-sprayed coating, Fig. 5c, shows a fairly homoge-
neous structure with a high packing density. The typical
layered structure results from oxide stringers between
the lamellae, indicating an oxidation of the molten parti-
cles. Table 7 illustrates the coating porosity content, the

Fig. 5. Tribaloy©-400: (a) optical micrograph of the as-sprayed coating; Fig. 6. Cr3 C2 –25%NiCr: (a) optical micrograph of the as-sprayed coating;
(b) X-ray diffraction patterns of powder; (c) X-ray diffraction patterns of (b) X-ray diffraction patterns of powder; (c) X-ray diffraction patterns of
the as-sprayed coating. the as-sprayed coating.
 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55
upper surface average roughness and its average micro-
hardness.
3.1.2. Cr3 C2 –25%NiCr
EDS analyses confirmed the attended chemical compo-
sition of the powder. The X-ray diffraction patterns of the
feedstock powder and the as-sprayed coating are displayed
in Fig. 6. A significant peak, characteristic of a substan-
tial amount of elemental chromium (Cr), is observed on
the coating and on the powder spectra. The intensities of
Cr3 C2 peaks are similar to those of the powder, and Cr3 C
and Cr7 C3 peaks are not observed. However, minor Cr3 Ni2
peaks are observed. These results confirm that dissociation
of carbides during the spraying does not significantly oc-
cur. A broad maximum in the range of 42–44 2θ seems to
indicate an amorphous phase in the deposit. Therefore, it
Fig. 7. WC–12%Co: (a) optical micrograph of the as-sprayed coating; (b)
X-ray diffraction patterns of powder; (c) X-ray diffraction patterns of the
as-sprayed coating.
49
is considered that nickel–chromium alloy and some Cr3 C2
carbide are melted and some amorphous phase forms, as
precised by Otsubo et al. [29,30].
The Cr3 C2 –25%NiCr coating exhibits a fairly high hard-
ness due to Cr3 C2 , among other characteristics, Table 7.
3.1.3. WC–12%Co
The properties and performances of tungsten carbide
cobalt coatings are attributed to a complex function of
carbide size, shape and distribution, matrix hardness and
toughness, and solution of carbon in the cobalt matrix.
A coating should hence retain a large volume fraction of
finely distributed tungsten monocarbide (WC) to achieve
optimum wear properties. This is largely dependent on the
Fig. 8. Typical evolution of the friction coefficient vs. the sliding distance.
50 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55

minimizing of decarburization of WC, which potentially

Variability,
σ/µ (%)

occurs at the high temperatures associated with thermal

6.11

spray processes [31,32].

7.5
10
10

The manufactured coatings contain a high concentra-

Hard chromium plating

tion of tungsten monocarbide crystals, namely WC, as

Friction coefficient,

distinguished by the higher proportion of dark gray phase,

Fig. 7a. X-ray diffraction analysis confirms also the pres-
0.02
0.02
0.01
0.01
0.01

ence of a larger percentage of WC, Fig. 7b and c. This

result derives from the optimization of the spray pa-
±
±
±
±
±
µ±σ
0.23
0.23
0.18
0.20
0.21

rameters, which limits the decomposition process. X-ray

diffraction pattern also indicates a substantial amount
of W2 C, but did not reveal substantial amounts of brit-
Variability,

tle cobalt containing-subcarbides in the coating, such as

Co3 W3 C, Co6 W6 C, Co6 W4 C, etc. [33]. Instead, it shows
σ/µ
11
11
9
9
10

a broad maximum between 40 and 48 2θ, which is very

likely characteristic of microcrystalline or amorphous
materials [34]. The cobalt and excess carbon are proba-
Friction coefficient,

bly present in the coatings in an amorphous states. The

WC–12%Co

coating is very hard and presents a low rate of porosity,

0.03
0.02
0.02
0.02
0.02

Table 7.
±
±
±
±
±
µ±σ
Evolution of the average friction coefficient of several coatings vs. the applied load and the sliding velocity for POD experiments

0.29
0.23
0.21
0.21
0.26

3.2. Friction and wear behaviors

Variability,

3.2.1. Pin-on-disc experiments

σ/µ (%)

Fig. 8 displays a typical evolution of the friction co-

efficients versus the sliding distance. Table 8 synthesizes
12
8
8
10
10

the evolution of the average friction coefficients for each

coating. Whatever is the coating nature and the applied
Friction coefficient,

load, the average friction coefficients remain very simi-

Cr3 C2 –25%NiCr

lar, around 0.23. However, a weight loss is recorded for

0.02
0.02
0.03
0.02
0.02

the counter bodies of Tribaloy©-400 on the pins tested

±
±
±
±
±
µ±µ

under a low load (5 N). Increasing the load (i.e., from 5

0.25
0.23
0.23
0.21
0.23

to 10 and 20 N) causes significant weight losses for the

brass counter bodies of WC–12%Co and Cr3 C2 –25%NiCr
coatings. This can be explained by the high hardnesses of
Variability,
σ/µ (%)

cermet materials, which are mainly due to the shape, the

µ: average value from 428 data points; σ: associated standard deviation.

quantity, and the distribution of carbides, as well as their

11
9
10
10
10

behavior under various levels of loads. However, it should

Friction coefficient,
Tribaloy©-400

0.02
0.02
0.02
0.02
0.02
±
±
±
±
±
µ±σ
0.23
0.21
0.20
0.23
0.23
Sliding velocity
(m s−1 )

0.14
0.84
0.7
0.7
0.7
Load
(N)

5
10
20
10
10
Table 8

Tests

P1
P2
P3
P4
P5

Fig. 9. Weight loss of the counter bodies rubbing against the coated pins.
 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55 51

be noted that the weight losses of counter bodies are even
more significant in case of hard chromium deposits, Fig. 9.
In all cases, as the testing load was increased, a tendency
towards a transition in wear behavior was revealed. At low
loads, the increase of friction coefficient can be explained
by an adhesive mechanism which lead to surface polish-
ing. For higher loads, the observed decreasing of friction
coefficients after the initial break-in can be attributed
to crushing and aggregation of the debris due to frag-
mentation of mating asperities, producing a “third” body
acting as a solid lubricant [1,35]. The same mecha-
nism is very likely noted when the sliding velocity
decreases.
Fig. 10 shows the scar surfaces of coatings tested for
various levels of load. Pull-outs of matter are also observed
on the brass counter bodies, characterized by specific widths
and depths of scars for each coated pin and each condition
test. The depths and widths of scar surfaces increase when
the applied normal load is increased (i.e.,∼96 ␮m width,
maximum value).
3.2.2. Amsler experiments
The Amsler tests permit to evaluate the wear rate of
the coatings by recording the coated sample weight losses,
as well as by analyzing the surface damages, under var-
ious applied loads. Fig. 11 shows a typical example of

Fig. 10. Optical views of the scars formed on the counter samples (brass)/HVOF coated pins.
52 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55

Fig. 11. Typical evolution of the moment vs. the sliding distance.

Table 9
Evolution of the dimensionless moment and the wear work vs. the applied load for Amsler experiments
Tests Load Tribaloy©-400 Cr3 C2 –25%NiCr WC–12%Co Hard chromium plating
(N)
Moment Wear Moment Wear Moment Wear Moment Wear
(N m) work (N m) work (N m) work (N m) work
A1 245 30 × 10−2 1 25 × 10−2 0.72 15 × 10−2 0.66 12 × 10−2 0.28
A2 490 41 × 10−2 1 21 × 10−2 0.54 19 × 10−2 0.51 19 × 10−2 0.31
A3 735 37 × 10−2 1 27 × 10−2 0.78 24 × 10−2 0.66 27 × 10−2 0.48

the evolution of the friction moment according to the slid- by partial delamination of coatings and causing grooves,
ing distance (i.e., 2500 m in the case of a WC–12%Co Fig. 13a.
coating in this example). Such an evolution explains why, In comparison to the HVOF carbide-based coatings, the
during the tests, the samples cross a grinding period, re- chromium plating was severely damaged. Significant frac-
sulting in a temporary increase of the moment value be- tures and very large and deep grooves were worn into sur-
cause of the high friction at the mating surfaces, Table 9. faces: the electroplated chromium is more easily abraded
A stability of the moment is reached thereafter, due to the than the carbide-based coatings, Fig. 13d.
reduction in friction of the new mating polished surfaces. It should be emphasized that, with regard to hardness,
When increasing the load, friction becomes increasingly wear and abrasion resistance, HVOF sprayed WC–12%Co
higher and is correlated to a weight loss of the coatings, coatings are superior to Tribaloy©-400 and Cr3 C2 –25%NiCr
Fig. 12. This is due primarily to wear and fatigue of the sprayed coatings, and far superior to electrodeposited hard
materials. chromium.
From a general point of view, the worn surfaces of
coatings show a continuous transferred brass film formed
on the coated surfaces, Fig. 13. The worn surfaces of
WC–12%Co and Cr3 C2 –25%NiCr coatings reveal an evi-
dence of grain pull-out, or scratching. Hard particles (i.e.,
carbides) embedded in the surface layer acted as abrasive
grains wearing samples and counter samples, Fig. 13c.
With increasing the load, more material is removed and
more important becomes the effect of the third body
abrasion: higher the wear of the coating and the counter
sample are. Compared to Cr3 C2 –25%NiCr worn surfaces,
the wear tracks on WC–12%Co coating surfaces show
little evidence of scratching and fractures, Fig. 13b. Com-
pared to carbide-based coatings, Tribaloy©-400 coatings Fig. 12. Evolution of the weight loss of the coated samples vs. the applied
appear more ductile and exhibit severe wears, occurring load.
 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55 53

Fig. 13. Typical SEM micrographs of the worn surfaces of the coatings (V = 0.52 m s−1 ).
54 T. Sahraoui et al. / Journal of Materials Processing Technology 152 (2004) 43–55
4. Conclusions
The results of the present study on HVOF sprayed coat-
ings and electrodeposited chromium can be summarized as
follows:
• From a general point of view, HVOF carbide-based coat-
ings exhibit higher hardnesses and superior performances
in wear resistance than hard chromium coatings.
• In comparison to chromium plating, with regard to
hardness, wear and abrasion resistance, HVOF sprayed
WC–12%Co coatings were far superior.
• In the case of shafts repair, hard chromium plating process
proved to be time consuming and to involve high costs.
High hardness and good wear resistance performances of
WC–12%Co HVOF sprayed coatings support their can-
didature for the replacement of hard chromium plating in
this field.
Acknowledgements
The authors gratefully thank F. Pendrak and O. Lande-
marre (LERMPS) for their very valuable help. LERMPS
is a member of the Institut des Traitements de Surface de
Franche-Comté (ITSFC, Surface Treatments Institute of
Franche-Comté), France. ANVAR (Agence Française de
l’Innovation, French Agency for Innovation) is gratefully
acknowledged for its financial support under grant program
No. J0205019I. 2002.
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