Carbon and Oxygen Addition Influence on NiCr Coatings Obtained by TVA Technology

NiCr composite coatings on stainless steel were obtained by the simultaneous deposition of Cr and Ni, using thermionic vacuum arc (TVA) technology. The main aim of this paper is to study the influence of graphite and oxygen incorporation on the structural, mechanical, and tribological properties of the resulting coatings. The deposition geometry was designed to maintain a relative constant Cr/Ni ratio while inducing a controlled compositional gradient in carbon content. An additional batch of samples was synthesized under reactive conditions by introducing a controlled O2 flow while maintaining the same plasma parameters during deposition. The coatings were deposited on both Si wafers and AISI 304 stainless steel substrates. The elemental composition and phase structure were analyzed by scanning electron microscopy- energy dispersive spectroscopy (SEM-EDS) and grazing-incidence X-ray diffraction (GIXRD), revealing the formation of mixed CrNi intermetallic phases, nickel carbide (Ni3C), and, under reactive conditions, chromium and nickel oxides. Increasing the oxygen content led to a progressive structural transition from metallic–carbide mixtures to predominantly crystalline oxide phases. Tribological performance was evaluated using a ball-on-disk tribometer, and the results demonstrated a significant reduction and stabilization of the friction coefficient for oxygen-containing coatings, together with enhanced wear resistance. SEM and EDS analyses of the wear tracks confirmed the formation of protective oxide layers that effectively reduced coating removal during sliding. Nanoindentation measurements revealed a substantial increase in hardness from ~4 GPa for binary Cr–Ni coatings to ~9 GPa for ternary Cr–Ni–C films, with the highest hardness values obtained for oxygen-enriched coatings. The results highlight the synergistic role of carbon and oxygen in tailoring the microstructure and enhancing the mechanical and tribological performance of Cr–Ni-based composite coatings deposited by TVA, demonstrating their potential for protective applications under demanding operating conditions. This work demonstrates that controlled oxygen incorporation during TVA deposition can be used as an effective tool to tailor simultaneously the phase composition, surface chemistry, mechanical response, and tribological behavior of Cr–Ni–C coatings without compromising coating integrity.