Plasma Spraying NiCoCrAlY-Cr2O3-AgMo Coatings: Fabrication and Tribological Mechanisms

The increasing demand for high-performance aircraft engines has led to a greater emphasis being placed on advanced sealing coating technologies. Developing long-life, self-lubricating, and wear-resistant coatings is of significant research value. This study focuses on the fabrication of a novel self-lubricating and wear-resistant NiCoCrAlY-Cr2O3-AgMo composite coating. This coating was deposited onto a GH4169 substrate utilizing plasma spraying. Scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS) and X-ray diffraction (XRD) methods were employed to characterize the elemental composition and microstructure of the fabricated NiCoCrAlY-Cr2O3-AgMo composite coating. Microhardness measurements across the coating cross-section indicated a gradual increase in hardness from the GH4169 substrate to the NiCoCrAlY-Cr2O3-AgMo coating. The average hardness of the GH4169 substrate was 413.92 HV0.2, while the CoNiCrAlY bonding layer region exhibited an average hardness of 467.60 HV0.2. The NiCoCrAlY-Cr2O3-AgMo coating itself demonstrated an average microhardness of 643.22 HV0.2. Room temperature friction tests indicated that the average coefficient of friction (COF) of the GH4169 substrate was 0.665. In contrast, the NiCoCrAlY-Cr2O3-AgMo coating exhibited a significantly lower average COF of 0.16, representing a 75.94% reduction compared to the uncoated GH4169 substrate. High-temperature friction tests were conducted at 400 °C, 500 °C, and 600 °C, indicating average COF values of 0.438, 0.410, and 0.268, respectively, for the NiCoCrAlY-Cr2O3-AgMo coating. Specifically, at 600 °C, the formation of a lubricious NiMoO4 tribofilm on the coating surface was observed. This tribofilm effectively reduced the wear rate of the GH605 pin to 2.78 × 10−6 mm3/N·m, highlighting the potential of the NiCoCrAlY-Cr2O3-AgMo coating to reduce wear in high-temperature sliding contact applications.