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Multicarbide Evolution and High-Temperature Failure Mechanisms of Non-spherical WC-Reinforced Ni-Based Coatings
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DOI：10.1007/s11666-026-02310-6.png)
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Abstract
En 中文
The service life of hot-rolling descaling rollers is severely limited by premature failure under synergistic high-temperature friction, wear, and alternating loads. Herein, non-spherical WC particles replaced conventional spherical WC to fabricate Ni-based composite coatings via plasma arc surfacing, so as to reveal the regulation mechanism of WC dosage on multicarbide evolution and high-temperature failure mechanisms. With WC contents of 30-65 wt.%, the microstructure transformed from sparse carbide dispersion to uniform multiphase refinement and ultimately to brittle coarse carbide networks. The results confirm that WC content below 45 wt.% optimizes carbide distribution and refines microstructure. The optimized coating acquires a refined grain size of 27.1 μm, high microhardness of 827 ± 3 HV1.0, and a low wear rate of (3.719 ± 0.4) × 10−6 mm3/N m at 400 °C, maintaining excellent strength–ductility balance and better high-temperature performance than high-WC counterparts. Fine-grain strengthening, dense oxide films, and strong interfacial bonding jointly inhibit oxidative–adhesive wear and crack propagation. This study clarifies the linkage of non-spherical WC content, multicarbide evolution, and high-temperature performance, guiding high-performance wear-resistant coatings for hot-rolling components. Hot-rolling descaling rollers suffer severe wear and premature failure at high temperatures. We fabricated non-spherical WC-reinforced Ni-based coatings via plasma arc surfacing, leveraging anti-settling advantages. This work first reveals content-dependent multicarbide evolution, clarifies carbide morphology effects on mechanical response and wear behavior, and confirms WC below 45 wt.% optimizes microstructure and high-temperature performance.
Keywords:
failure mechanism
high-temperature fracture
multicarbide evolution
non-spherical WC
plasma arc surfacing
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