OBRABOTKAMETALLOV Vol. 28 No. 1 2026 126 TECHNOLOGY Wear resistance of plasma coatings formed by combined surface-thermal treatment methods: toward the design of hybrid machine-tool equipment Egor Zverev 1, a, Vadim Skeeba 1, b, *, Ayagma Zhargalova 2, c, Nikita Vakhrushev 1, d, Andrey Popkov 1, e 1 Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation 2 Bauman Moscow State Technical University, 5/1 2nd Baumanskaya St., Moscow, 105005, Russian Federation a https://orcid.org/0000-0003-4405-6623, zverev@corp.nstu.ru; b https://orcid.org/0000-0002-8242-2295, skeeba_vadim@mail.ru; d https://orcid.org/0000-0002-6251-1004, azhargalova@bmstu.ru; d https://orcid.org/0000-0002-2273-5329, vah_nikit@mail.ru; e https://orcid.org/0009-0006-5587-9990, andrej.popkov.2013@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2026 vol. 28 no. 1 pp. 114–129 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2026-28.1-114-129 ART I CLE I NFO Article history: Received: 17 January 2026 Revised: 08 February 2026 Accepted: 14 February 2026 Available online: 15 March 2026 Keywords: Plasma spraying Combined treatment High-energy heating by highfrequency currents Ceramic-metal coatings Mechanical mixtures Wear resistance Hybrid machine-tool equipment Integration of surface-thermal operations Funding The study was supported by the Ministry of Science and Higher Education of the Russian Federation (project FSUN2026-0005). Acknowledgements The research was carried out using the equipment of the Engineering Center “Design and Production of High-Tech Equipment”. ABSTRACT Introduction. In the context of the increasing demand in the modern machine-tool industry for the development of hybrid machine-tool equipment integrating mechanical and surface-thermal operations, the study of combined technologies for the formation of wear-resistant coatings becomes highly relevant. The integration of fundamentally diff erent processing methods – mechanical shaping and high-energy surface-thermal modifi cation – on a single machine platform represents a promising direction for improving the effi ciency and quality of manufacturing processes. Plasma spraying supplemented by high-energy heating with high-frequency currents (HFC) or the formation of composite ceramic–metal coatings from mechanical mixtures creates the prerequisites for designing multifunctional hybrid systems that meet the requirements of Industry 4.0. However, the comparative eff ectiveness of various combined coating treatment options under tribological loading has not been suffi ciently studied to date. The purpose of the present work is to conduct a systematic comparative study of the wear resistance of plasma coatings formed under diff erent conditions of combined spraying technology under dry sliding friction , and to formulate recommendations for the design of advanced hybrid machine-tool equipment. Methods. Plasma coatings sprayed from PG-12N-01, PG-S27, and PGN-V3K powders were investigated, as well as coatings subjected to additional high-energy induction remelting and coatings from mechanical mixtures of metal powder and aluminum oxide (Al₂O₃). Spraying was performed with a PUN-3 plasma torch at optimized conditions. High-energy heating was carried out using a VChG 6-60/0.44 generator at a frequency of 440 kHz. Wear resistance tests were conducted under continuous dry sliding friction against a VK8 cemented carbide indenter at a load of 20 N. The wear criterion was the volume loss of the coating material, determined by measuring the wear scar width with a UIM-21 toolmaker’s microscope. The coating microstructure was studied by optical metallography. Results and discussion. It was established that remelted nickel coatings of the PG-12N-01 grade exhibit wear resistance exceeding that of the initial non-remelted coating by 35%. At the same time, remelting of PG-S27 high-chromium cast iron coatings led to a 20 % decrease in wear resistance due to the formation of an unfavorable dendritic structure. Coatings based on ceramic–metal mechanical mixtures showed the best results: the nickel–ceramic mixture PG-12N-01 (20 %) + + 15A (80 %) exceeded the baseline value by 44 %, while the cobalt–ceramic mixture PGN-V3K (20 %) + + 15A (80 %) provided a 30 % increase in wear resistance compared to the initial cobalt alloy coating, with wear practically ceasing after the run-in period. The structure of ceramic–metal coatings is characterized by a uniform distribution of fi ne oxide ceramic particles in a metallic matrix, which ensures high tribological performance of the composite. The research results form an experimental basis for the design of next-generation hybrid machine-tool equipment integrating mechanical processing and surface-thermal technological operations. For citation: Zverev E.A., Skeeba V.Yu., Zhargalova A.D., Vakhrushev N.V., Popkov A.S. Wear resistance of plasma coatings formed by combined surface-thermal treatment methods: toward the design of hybrid machine-tool equipment. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2026, vol. 28, no. 1, pp. 114–129. DOI: 10.17212/1994-6309-2026-28.1114-129. (In Russian). ______ * Corresponding author Skeeba Vadim Yu., Ph.D. (Engineering), Associate Professor Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation Tel: +7 383 346-17-79, e-mail: skeeba_vadim@mail.ru
RkJQdWJsaXNoZXIy MTk0ODM1