Microstructure, phase evolution, and wear behavior of NbC reinforced Cr3C2-NiCr coatings deposited by HP-HVOF

High-performance wear-resistant coatings are required for severe service conditions in petrochemical and Oil & Gas applications. Conventional WC-based coatings rely on critical raw materials, motivating the development of alternative carbide-reinforced systems. This study investigates the microstructure, phase evolution, mechanical properties, and abrasive wear behavior of HP-HVOF sprayed Cr 3 C 2 –25NiCr coatings reinforced with NbC-based additions (NiNbC, CrNbC, and FeNbC). Dense lamellar coatings with low porosity were obtained for CrNbC and FeNbC, whereas NiNbC produced thinner and more heterogeneous layers due to reduced deposition efficiency. X-ray diffraction confirmed the retention of thermally stable NbC and revealed partial decarburization of Cr 3 C 2 during spraying. FeNbC and CrNbC coatings showed higher microhardness (945–1003 HV 0.3 ), while NiNbC exhibited lower hardness but improved abrasive wear resistance. The results indicate that wear performance is primarily governed by microstructural features, including matrix toughness and carbide–matrix bonding, demonstrating the potential of NbC-reinforced Cr 3 C 2 -based coatings as alternatives to conventional carbide systems.