Wear 263 (2007) 691699

Short communication
Wear performance of sandwich structured WCCoCr thermally
sprayed coatings using different intermediate layers
M. Hadad
a,
, R. Hitzek
b
, P. Buergler
b
, L. Rohr
a
, S. Siegmann
a
a
EMPA, Swiss Federal Laboratories for Materials Testing and Research, 3602 Thun, Switzerland
b
Stellba Schweisstechnik AG, 5605 Dottikon, Switzerland
Received 1 September 2006; received in revised form 29 November 2006; accepted 12 December 2006
Available online 23 May 2007
Abstract
Cermet based WCCoCr thermally sprayed coatings are known for their good wear and corrosion performance. Different intermediate layers
with various deposition processes were performed between cermet WCCoCr coatings to form a sandwich structure to enhance adhesion and to
damp particle impacts during erosion. As the outer cermet layer exhibits high hardness against abrasion whereas the intermediate layer is ductile to
damp the shock due to particle impact in erosion, sandwich coatings might have potential improvement in life time of coated tools used in mining,
drilling, cutting and grinding.
Adhesion tests were performed and the tribological behavior of cermet coating and sandwich structured materials was mainly investigated with
dry erosion and high pressure slurry jet erosion tests with 30

and 90

impinging angles to study wear mechanism and particle impact at interfaces

between coatings. In this work, the adhesive strength of different coatings was measured for each combination. Cermet coating, combinations
of NiCr 8020 and Ni-plating showed high strength value. In spite of the low erosive wear rate NiCr 8020, the metallographic examination
revealed many cracks within this coating due to the particle erosion at high pressures that has been found to drive microcracks through the interfaces
between splats leading to aking of the sprayed coatings. The electrochemically deposited interlayer showed better tribological performance under
metallographic observation, because of its homogeneous microstructure, since the electrochemical deposition does not provide splat formation.
Consequently, the absence of discrete interfaces limits crack initiation within the coating and at the interface. However, the microstructure of the
interlayer is known to be related to coating deposition process such as microsplats and oxide formation in spraying process. Therefore, the inuence
of microstructure on wear mechanism was investigated.
2007 Elsevier B.V. All rights reserved.
Keywords: Wear mechanism; Cermet WCCoCr; Thermally sprayed coating; Erosion; Sandwich structure; Nickel plating
1. Introduction
Cermet based WCCoCr thermally sprayed coatings have
proven to be interesting wear resistant coating materials since
the hard WC grains provides generally good bonding to the
metallic matrix, e.g. CoCr. The WC particles in the coating
lead to high coating hardness and high abrasive wear resistance,
while the metal binder CoCr supplies the necessary coating
toughness [1,2]. The cermet sandwich structured coatings, con-
sisting of a cermet outer layer and ductile bond layer, might
have potential improvement in life time of coated tools used
in mining, drilling tunnels and grinding since the outer cermet

Corresponding author. Tel.: +41 332282963; fax: +41 332284490.

E-mail address: mousab.hadad@empa.ch (M. Hadad).
layer exhibits high hardness against abrasion whereas the bond
layer is ductile to damp the impact shock of particle during ero-
sion. A number of research papers reported a dependency of
erosion damage on the mechanical properties such as material
hardness [3,4] if the erodent solicitation is perpendicular to the
surface, or material toughness if the erosive materials are applied
in shearing solicitation. Subsequently, the abrasive wear resis-
tance of materials was found to increase generally with both
increasing hardness and fracture toughness [59]. The impinge-
ment erosion resistance of HVOF coatings can be explained by
the microjets formed by dividing bigger jets into smaller jets
that cannot penetrate easily the hard tungsten carbide particles
where the repetitive high intensity of the striking jet weakens
the matrix, which is then removed easily by microjets [10]. Dry
and slurry erosive wear mechanismof WCCoCr was reported
where the high impact of particles on the coating surface results
0043-1648/$ see front matter 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.wear.2006.12.057
692 M. Hadad et al. / Wear 263 (2007) 691699
Fig. 1. SEM micrograph of WCCoCr powder and the histogram of grain size distribution.
in cracks by fatigue at the subsurface leading to micro-cracked
coating. This is the mainly found dominating wear mechanism
of cermet coatings [1115]. Different deformation zones have
been determined caused by the impact of single solid particles on
laminated structure where bond coat is taken in sandwich [16].
A common feature of all thermal spray coatings is their lamel-
lar grain structure resulting fromthe rapid solidication of small
globules, attened fromstriking a cold surface at high velocities.
This structure is interspersed with oxide inclusions and porosity.
Most metallic coatings suffer oxidation during normal thermal
spraying in air [17]. However, we do not nd paper describing
wear mechanism at the interface between cermet coating and
bond coat, where the adhesion and tribological performance
of bond coat are associated for long life service of compo-
nents. Certain coatings cannot be used for some applications
because of their low and insufcient adhesive strength. Among
the most widespread adhesion test methods used are indentation
tests [18,19], shear tests [2023] and tensile adhesive strength
according to ASTM C633, ASTM F1147, ISO 14916 or EN
582 [2426]. We should also note that adhesion is not a constant
in practical applications, but rather a complicated property that
depends on loading conditions, coating thickness [16] and dif-
ferent parameters such as grit blasting to roughen the substrate
surface [2731]. Furthermore, the residual stresses due to the
mismatch in thermal and mechanical properties between coat-
ings and substrates are of special importance [3236]. This work
explored the tribological behavior of cermet coating and various
bond coats within sandwich structured cermet coatings under
different erosion conditions. Although that cermet coating and
combination with the interlayer NiCr 8020 showed quantita-
tively good wear and adhesion performance, the metallographic
observations revealed cracks parallel to interface in cermet coat-
ing, and propagating through the interfaces between splats in
the intermediate layer NiCr 8020. Theses cracks might lead
to coatings delaminating in life service. Combinations 4 and 5
with Ni-plating revealed quantitatively and qualitatively a better
wear and adhesion performance since no cracks were observed
within this coating. This is mainly due to its dense and homoge-
neous microstructure related to the deposition process that does
not provide discrete interfaces within the coating.
2. Cermet and bond coating materials
Cermet based WCCrCo coating was deposited by high
velocity oxy-fuel (HVOF) spraying on steel substrate (DIN
1.4313) that has been grit blasted with Al
2
O
3
grit of no. 36
mesh size to increase the substrate roughness to approximately
Ra =5.5 m promoting a good coating adhesion. Specimens
were degreased immediately prior to deposition. The specimens
dimension was 40 mm40 mm. Details of the HVOF param-
eters are given in Table 1. As the grain size and morphology
of WCCoCr powder have high impact on mechanical proper-
Fig. 2. Micrographs of Ni-plating within cermet coatings: (a) the grit blasted Ni-plated coating (combination 5) and (b) the Ni-plated coating as deposited and not
grit blasted (combination 4) between WCCoCr coatings.
M. Hadad et al. / Wear 263 (2007) 691699 693
Table 1
Spraying conditions of HVOF process
Spray gun Top-gun
Kerosene pressure (bar), ow rate (l/h) 2123, 2024
O
2
pressure (bar), ow rate (l/min) 2021, 8001000
N
2
pressure (bar), ow rate (l/min) 910, 1517
Spraying distance (m) 0.30.5
ties of the coatings. Scanning electron microscopy (SEM) and
Powder-shape

system by scanner [37,38] have been used in

order to characterize the grain morphology and statistical grain
size distribution that found to be 2050 m as shown in Fig. 1.
The porosity within the cermet coating was estimated by image
analysis to be around 2%. Different bond layers were deposited
on the rst cermet coating, and then a cermet top coating was
sprayed to formthe sandwich structure. NiCr 8020 and CoCr
were deposited by HVOF spraying on the rst cermet coating.
Nickel was electrochemically plated on the cermet coating with
optimized parameters to achieve a uniform and continuous Ni
layer. The thickness of the Ni layer was approximately 60 m.
The cermet coating surface previously exhibited a roughness
of Ra =5 m. After having deposited the Ni plating, half of
the Ni-electroplated samples were slightly grit blasted to reach
again a roughness of Ra up to 4.5 m, so-called Ni-plating-X
combination 5 in Table 2. The other Ni-electroplated samples
were not grit blasted to perform the combination 4 shown in the
cross-section in Fig. 2. Lastly, a cermet coating as top layer has
been deposited on all interlayer coatings with the same spraying
conditions shown in Table 1. The sandwich structure and inter-
layer morphology of combinations are shown in Fig. 3 in the as
sprayed condition. The mechanical properties of the steel sub-
strate, WCCoCr and interlayer coatings such as hardness and
Youngs modulus have been determined by low-load indentation
techniques [39,40] and are summarized in Table 2.
Fig. 3. Micrographs of cross-sectioned samples as sprayed. Micrograph of (a) cermet based WCCoCr sandwich structured coatings using an intermediate layer
(example cermet/NiCr/cermet), (b) NiCr 8020 HVOF intermediate layer morphology presenting some oxide layers between splats, (c) CoCr HVOF intermediate
layer morphology with some oxide layers between splats (dark lines), (d) Ni-plating morphology showing a dense and homogeneous coating and (e) cermet based
WCCoCr HVOF coating morphology.
694 M. Hadad et al. / Wear 263 (2007) 691699
Table 2
Mechanical characteristics of substrate, cermet and bond coating materials
Combinations and nomenclature Characteristics of substrate and bond coatings
Interlayer Coating system Thickness (m) Youngs Modulus (GPa) Hardness, Hv 0.3
Mean S.D. Mean S.D.
1. Cermet/steel HVOF 500
2. Cermet/NiCr/cermet NiCr 8020 HVOF 110 100 14 387 42
3. Cermet/CoCr/cermet CoCr HVOF 140 144 13 697 63
4. Cermet/Ni-plating/Cermet Ni-Plating Electroplating 50 243 15 516 31
5. Cermet/Ni-plating-X/cermet Ni-Plating-X Electroplating 50 243 15 516 31
6. Substrate DIN-1.4313 210 5 260 28
7. Cermet WCCrCo HVOF 250 266 12 1432 141
3. Experimental procedure
3.1. Tensile adhesive strength
According to the standard test EN 582, coated specimens of
25 mmdiameter were joined with cylindrical counter parts using
an adhesive agent and cured at a temperature of 210

C. The ten-
sile load was applied on a Universal Epprecht-Multitest tensile
machine. The mean adhesive strength values were calculated
from ve tests performed under the same conditions as:

max
(MPa) =
F
A
, (1)
where Fis the maximumloadat rupture andAis the cross-section
area of the specimen.
3.2. Slurry erosion tests
A liquid jet impingement erosion test has been performed
similar to the principle of ASTMG73 using sand particles intro-
duced through the water jets nozzle by a powder feeder as shown
in Fig. 4. Two different incident angles of 90

and 30

between
the nozzle axis and the sample surface were used in order to sim-
ulate normal and shear slurry erosive wear, respectively. The test
parameters are shown in Table 3.
3.3. Dry erosion tests
The dry erosion experiments were conducted using a grit-
blasting machine, which is based on pressurized air to accelerate
sand particles as shown in Fig. 5. A blocky shaped white Al
2
O
3
was used as erodent particles. However, the details of test param-
eters are given in Table 3. Two incident angles of 90

and 30

between the nozzle axis and the sample surface were used in
order to simulate steep and at impact erosion, respectively.
Wear rates from three erosion tests are averaged and expressed
by mass loss per minute. The test samples were weighed before
and after testing to an accuracy of 0.02 mg and were mounted at
xed angles of 30

and 90

.
Fig. 4. Schematic presentation of liquid impingement erosion equipment.
Fig. 5. Schematic presentation of dry sand erosion test.
Table 3
The test parameters of dry and slurry erosion experiments
Test Erodent
material
Erodent
size (m)
Flow rate
(water) (l/min)
Flow rate
(erodent) (g/min)
Velocity
(m/s)
Stand off
distance (mm)
Nozzle diameter
(mm)
Pressure
(bar)
Exposure time
(min)
Slurry erosion Al
2
O
3
75 +45 13.6 9.52 147 100 1.4 250 38
Dry erosion Al
2
O
3
1000 +500 378 12 70 7.5 3.5 25
M. Hadad et al. / Wear 263 (2007) 691699 695
Fig. 6. Determination of tensile adhesive strength according to the standards
EN 582 or ISO 14916 for different sandwich combinations (combinations of
materials see Table 2).
4. Results and discussion
The tensile adhesive strength was calculated and presented
in Fig. 6. Sandwich combination 3 showed the lowest bond
strength, whereas the difference between the other sandwich
combinations was small. The failure fracture of coatings
occurred adhesively within the glue and the substrate except
combination 3 has failed cohesively within the CoCr intermedi-
ate layer. This is due to the presence of weak interfaces between
splats and pre-existing oxide layers within the coating where the
adhesive energy of coating at the interfaces was greater than that
stocked in between splats. The investigations on bond strength
and tribological behavior of coatings allowbetter understanding
the mechanical and wearing performance.
Fig. 7. Results of (a) dry erosion and (b) slurry erosion rate with error bars prior
to particle impact of 30

and 90

.
4.1. Dry and slurry erosion rate
The results of wear resistance in dry erosion shown in Fig. 7a
under the impact angle of 30

showed only small differences

between combinations 1, 2, 4 and 5. The combination 3 with
Fig. 8. SEM micrographs of the upper surface of sandwich combinations under dry erosion conditions. (a) WCCoCr, (b) Ni-Plating, (c) NiCr 8020 and (d)
CoCr.
696 M. Hadad et al. / Wear 263 (2007) 691699
Fig. 9. Micrographs of the cross-sectioned sandwich combination under dry erosion with different angles of particle impact.
CoCr as interlayer showed the lowest wear resistance, whereas,
the combination 2 with NiCr 8020 interlayer showed the high-
est wear resistance under impact angle of 90

. While trend of
wear rate in slurry erosion under 30

showed higher than that

under 90

which is similar to that trend found in metallic coating

[41]. This can be explained by:
The microjets formed by dividing bigger jets into smaller
jets including the small erodent particles (75 +45 m) can-
not penetrate easily the hard tungsten carbide particles. The
repetitive high intensity of the striking slurry jet weakens the
metallic matrix leading to get it initially removed and peeled-
off WC grains and this is in agreement with literature [10].
M. Hadad et al. / Wear 263 (2007) 691699 697
Fig. 10. Micrographs of the cross-sectioned sandwich combinations under slurry erosion with different angles of impact.
The surface exposed under 30

(7 mm
2
) was up to four times
bigger than that of 90

(31 mm
2
). This behavior was not the
case under dryerosionbecause the exposedsurface under both
angles covered the whole specimen of 40 40 of dimension.
The erodent content in water can play also a role where it
has found in similar conditions, the difference in wear rate at
the steep and normal angles was very slight [42].
Previous work under slurry erosion showed wear rate of cermet
coating at 30

and 90

in the same order of magnitude. The wear

erosion rate in slurry erosion is about 10 times smaller than that
in dry erosion under both angles as shown in Fig. 7b, which is in
agreement with the literature [11]. This difference is mainly due
to erodent size and to its kinetic energy. In dry rather in slurry
erosion, the difference in wear resistance between combinations
698 M. Hadad et al. / Wear 263 (2007) 691699
was not very high, because of the low thickness of intermediate
coating compared to the whole thickness of sandwich structure
(510%) and to the experimental scatter. In order to under-
stand wear mechanism and erosion effects on the interfaces,
metallographic observations in the SEM have been performed
on the cross-sectioned and surface of eroded specimens. The
cross-sections were carefully prepared using liquid inltration to
avoid introducing additional defects during the metallographic
preparation.
4.2. Wear mechanism
The surface of the cermet (WCCoCr) presented in Fig. 8a
shows the presence of cutting marks without cracks or splat
debonding for instance, and indicates mainly ductile behavior
in dry and slurry erosion condition with different angles. This
initial observation of wear mechanismunder different angle was
in accordance to the literature found [11,15]. Fig. 8b shows the
eroded Ni-plating presenting some over lapping and plough-
ing, whereas Fig. 8c shows very important plastic deformation
and some debonded splats. This is related to the mechanical
properties of the Ni-plating and to the process of spray depo-
sition respectively. Fig. 8d shows the eroded surface of bond
coat CoCr and its interface to cermet coating, which reveals a
dramatic delamination at the interface between bond coat and
cermet layer and the presence of many cracks within the bond
coat.
The observations on the cross-sectioned samples are pre-
sented in Figs. 9 and 10 that show different wear mechanisms
according to the impact angle and erosive solicitations by slurry
jet and dry erosion.
4.2.1. Wear mechanism of dry erosion
The cross-sections of combination 1 (WCCoCr) showed
cracks propagating parallel to the interface between the coating
and the substrate and they generally tend to propagate through
the grains leading to peeling off WC grains [14] and subsequent
spallation of akes. In combination 2 and close to the bond coat,
cracks were found only within the bond coat and the interfaces
between coatings were not affected. This might be due to the
stress transition in the plastic zone [16] by the repetitive particle
impact, whichallows crackinitiationbyfatigue throughthe bond
coat. Combination 3 with CrCo as bond coat showed a dras-
tic failure through the bond coat and many cracks propagated
through the interfaces between splats. However, combinations
4 and 5 revealed high performance because of the absence of
cracks within the coating and of delamination at the interface.
4.2.2. Wear mechanism of slurry erosion
The repetitive particle impact at high-pressure results on the
coatinguctuatinghighstress whichover comes the deformation
zone. Micrographs of combinations 2 and 3 do not show only
cracks propagating through interfaces between splats, but also
through the interface between the bond coat and cermet coating.
The effect due to particle impact angle was more pronounced in
these two combinations than in the other systems. Slurry erosion
with 30

of the combinations 4 and 5 showed no cracks within

coatings and interfaces. Consequently, these combinations had
better wear performance. The combination 4 under 90

revealed
a bond coat spallation in a very small area and this may be due
to the lower mechanical anchoring by low interfacial roughness
of this bond coat compared to the roughened one in combination
5.
However, as comparative results, micrographic observations
revealed that combination 5 with the bond coat Ni-plating-X
showed the smallest defects among all combinations. There-
fore, the tensile adhesive strength and the mechanical properties
of this bond coat allow assuming that bond coat could have the
highest wear performance in sandwich structure under different
erosive solicitations. Our explanation of this good behavior is
mainly attributed to mechanical properties and to the homoge-
neous microstructure [43] since the electrochemical deposition
process results in a strong interface to cermet coating and does
not provide discrete interfaces within Ni-layer.
5. Conclusions
In this work, adhesion and wear behavior of cermet and dif-
ferent intermediate coatings within sandwich structured based
cermet coatings were studied. Cermet, combinations with
NiCr 8020 HVOF deposited and Ni-plating electrochemically
deposited coating showed high adhesive strength value. The
blasted interface of Ni-plating-X did not show higher adhesion
value rather a difference in wear performance.
Different wear mechanisms were found and discussed. Com-
bination with bond coat CoCr does not showonly lowadhesive
strength value and cohesive failure, but also a drastic delamina-
tion and many cracks after erosion test. In spite of that cermet and
combination with interlayer NiCr 8020 showed high wear and
adhesionperformance, the metallographic observations revealed
cracks within the coating and propagating through interfaces
between splats of NiCr 8020 which might lead to coatings
delaminating in life service. Therefore, combinations 4 and 5
with Ni-plating revealed quantitatively and qualitatively bet-
ter tribological and adhesion performance. This was attributed
mainly to the homogeneous microstructure since the electro-
chemical deposition process does not provide discrete interfaces
between splats as for sprayed coatings, subsequently; it can limit
the crack propagation.
Acknowledgements
We would like to thank the CTI commission for the sup-
port under Lewis project No. 5942.3 and Dr. B. Moser for the
English correction as well as A. De Meuron for helping in the
metallographic investigations, R. Egli and B. von Gunten for
the sample spraying and C. Schwendimann for performing the
different wear tests.
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