Microstructure and bond strength of niobium carbide coating on GCr15 prepared by in-situ hot press sintering

The hardness and adhesion of protective hard coatings to the substrate are the most important parameters that influence the performance of the tool. Herein, we propose an effective strategy, by in-situ hot press sintering, to fabricate a novel niobium carbide coating with high hardness and excellent interfacial bond strength on GCr15. The coating is composed of Nb2C, NbC, and α-Fe phases. The volume fraction of niobium carbide (Nb2C and NbC) phases reaches 93%. Along the direction of coating thickness, the grain morphology of niobium carbide changes from equiaxed (Nb2C) to columnar (NbC), and then to equiaxed (NbC), presenting a gradient microstructure. The coating/substrate interface displays an excellent macro/micro interface. The formation of the gradient microstructure is attributed to the nucleation-growth process controlled by the carbon concentration gradient diffusion. The novel gradient coating can simultaneously achieve superhardness (20.2 ± 0.3 GPa) and excellent bond strength (>210 ± 20 MPa). The excellent bond strength is mainly attributed to the in-situ formation of the coating and the gradient microstructures. The tensile test results show that the fracture mechanism of the niobium carbide coating on GCr15 is mainly a brittle fracture of niobium carbide coating and a small amount of coating debonding.