Effect of WC particles with different shapes during plasma spray on the properties of Fe-based composites coatings

The WC particles reinforced Fe-based spray welding layer was fabricated on the surface of 45 steel by plasma arc spray welding technology. The WC particles were irregular polyhedral and spherical, which were fed into the tail of the molten pool. The microstructure, phase composition, microhardness, and dry -sliding wear resistance of the coating were evaluated. The results show that the microstructure of the composite coating exhibits a hypoeutectic structure in addition to the WC, and the spherical WC particles are better preserved than the irregular polyhedral WC particles. The coating added with spherical WC particles has the best wear resistance, which is 1.28 times that of the coating added with irregular polyhedral WC particles.