Wear

Wear resistant coatings for your needs

Wear Coatings

We have over 300 coatings in our portfolio, of which many were created to provide wear resistance. Wear resistant coatings solve industries challenges related to abrasion, erosion, galling and fretting. Most of these components were designed using carbon steel, stainless steel, tool steel or aluminum which may have been protected by anodizing, nitriding, carburizing or plating with hard chrome. We can improve the life of these components and the quality impact on your products by utilizing carbide, ceramic, cermet or metallic thermal spray coatings or by laser cladding / hardfacing.

Popular Types of Wear Resistant Coatings

Carbide

Carbide coatings are used to protect a part against abrasion, erosion, galling, and fretting. Most coatings are applied by high velocity thermal spray processes but plasma can be used. They improve the surface features of the part to improve hardness, retain surface characteristics, provide durability and toughness and resist metal to metal adhesion. There are numerous types of carbide coatings which fall into these main families:

  • Tungsten carbide - cobalt
  • Tungsten carbide - cobalt/chrome
  • Tungsten carbide - nickel
  • Tungsten carbide / chromium carbide - nickel
  • Chromium carbide
  • Chromium carbide - nickel/chrome

Ceramic

Ceramic coatings also called oxide coatings are used to protect a part against abrasion, sliding wear, fretting and galling. Ceramic coatings also offer corrosion resistance when paired with sealers, so they can be selected to provide wear resistance when in contact with corrosive fluids. Ceramic coatings are applied by plasma spray and detonation gun processes. Listed below are the common types of ceramic coatings.

  • Aluminum oxide
  • Aluminum oxide / Titanium oxide
  • Chromium oxide
  • Chromium oxide / Titanium oxide
  • Chromium oxide / Titanium oxide/ Silicon oxide
  • Yttrium oxide
  • Zirconium oxide
  • Zirconium oxide / Yttrium oxide

Cermet

Cermet coatings are designed to function like carbide and ceramic coatings but at higher temperatures, up to ~1100°C (~2000°F). The binder is modified by using superalloys or MCrAlY powders, where “M” can be nickel, cobalt or a combination of both. The modified binder is able to survive oxidation at the higher temperatures. Listed below are some example compositions.

  • MCrAlY plus aluminum oxide
  • MCrAlY plus chromium carbide
  • NiCrBSi plus tungsten carbide
  • Superalloy plus aluminum oxide
  • Superalloy plus oxide and carbide blends

Metal Alloy

Metal alloy coatings have a base alloy that is corrosion resistant plus some hard phases for wear resistance. Various methods of thermal spraying can be used to apply the metal alloy coating. Some common chemistries are listed:

  • Nickel superalloy plus chromium carbide
  • Nickel superalloy plus tungsten carbide
  • Cobalt alloys plus tungsten carbide

Laser Cladding / Hardfacing

Laser cladding’s metallurgical bond, consistent chemistry and ductility combat wear and corrosion in areas where thermal spray coatings and chrome plating fall short due to brittleness, permeable morphology and mechanical bond. Numerous materials and blends are available with some popular chemistries listed below:

  • Stainless steel plus tungsten carbide
  • Nickel alloys plus tungsten carbide
  • Nickel-based hardfacing alloys
  • Cobalt-based hardfacing alloys
  • Tungsten carbide composites