OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 27 No. 3 2025 Fe-Ni-Al matrix, thereby reducing the barrier properties of the aluminum oxide layer formed during hightemperature oxidation. The weight gain during the oxidation resistance test results from the fixation of oxygen on the surface of the samples in the form of hematite Fe2O3 (Fig. 8, b). In general, the WC20 and WC40 composite coatings demonstrated high oxidation resistance at 700 °C. Their use allows for an 8.4 to 11.6-fold increase in the oxidation resistance of components made of Steel 45. Conclusions 1. For the first time, the influence of tungsten carbide powder particle size distribution on the production of WC/Fe-Ni-Al metalloceramic coatings on Steel 45 using electrospark deposition with a non-localized electrode was investigated. Tungsten carbide powder fractions of 1 ≤ WC ≤ 20 μm and 20 ≤ WC ≤ 40 μm were prepared via grinding in a planetary ball mill and subsequent sieve analysis. 2. The total weight gain values for samples WСn and WС20 were similar, while the weight gain rate was noticeably lower for W40. X-ray diffraction analysis revealed that the deposited coatings consisted of tungsten carbide, tungsten subcarbide (W2C), iron aluminide (Al86Fe14), ferronickel (FeNi), and BCC phases (AlNi, AlFe). It was shown that increasing the WC powder fraction size in the electrode resulted in enrichment of the coating matrix with aluminum, while the iron concentration decreased from 60 to 30 at.%. The coating structure corresponds to a metalloceramic composite. 3. The surface roughness of the coatings ranged from 5.87 to 8.23 µm, with a minimum value for the WC40 sample. The contact angle of the coatings ranged from 77.7 to 83.6±1.6°, with the lowest value observed for the sample produced using tungsten carbide nanopowder. 4. The microhardness of the coating surface ranged from 4.39 to 9.16 GPa, with the lowest value observed for the sample produced using tungsten carbide nanopowder. 5. This study demonstrated that tungsten carbide particle fractions ranging from 20 to 40 µm provide the best wear resistance and oxidation resistance of WC/Fe-N-Al coatings at 700 °C. It was shown that the use of such coatings increases the oxidation resistance of Steel 45 by up to 11.6 times and the wear resistance by 44 to 80 times. References 1. Wang X., Liu Z., Cheng K., Li J., Ning H., Mao J. High-temperature corrosion characterization of Ni-Al laser cladding: The effect of Al content and Fe. Journal of Thermal Spray Technology, 2024, vol. 33 (5), pp. 1417–1439. DOI: 10.1007/s11666-024-01782-8. 2. Wang Z., Zhang J., Zhang F., Qi C. Study on the microstructure and properties of a laser cladding Fe–Ni–Al coating based on the invar effect. Scientific Reports, 2024, vol. 14 (1), p. 11685. DOI: 10.1038/s41598-024-62306-6. 3. Munroe P.R., George M., Baker I., Kennedy F.E. Microstructure, mechanical properties and wear of Ni–Al–Fe alloys. Materials Science and Engineering: A, 2002, vol. 325 (1–2), pp. 1–8. DOI: 10.1016/S09215093(01)01403-4. 4. Datu-Maki A.S.I., Ciswandi, Hermanto B., Saptari S.A., Sudiro T. Structure and oxidation resistance of flame sprayed Fe–Ni–Al coating. Journal of Physics: Conference Series, 2019, vol. 1204 (1), p. 012128. DOI: 10.1088/1742-6596/1204/1/012128. 5. Manikandan R., Ponnusamy P., Nanthakumar S., Gowrishankar A., Balambica V., Girimurugan R., Mayakannan S. Optimization and experimental investigation on AA6082/WC metal matrix composites by abrasive flow machining process. Materials Today: Proceedings, 2023. DOI: 10.1016/j.matpr.2023.03.274. 6. Alidokht S.A., Wu L., Bessette S., Chromik R.R. Microstructure and tribology of cold spray additively manufactured multimodal Ni-WC metal matrix composites. Wear, 2024, vol. 538, p. 205218. DOI: 10.1016/j. wear.2023.205218. 7. Liao Z., Huang X., Zhang F., Li Z., Chen S., Shan Q. Effect of WC mass fraction on the microstructure and frictional wear properties of WC/Fe matrix composites. International Journal of Refractory Metals and Hard Materials, 2023, vol. 114, p. 106265. DOI: 10.1016/j.ijrmhm.2023.106265. 8. Yuan J., Wang Q., Liu X., Lou S., Li Q., Wang Z. Microstructures and high-temperature wear behavior of NiAl/WC-Fex coatings on carbon steel by plasma cladding. Journal of Alloys and Compounds, 2020, vol. 842, p. 155850. DOI: 10.1016/j.jallcom.2020.155850.
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