Lightweight TiC/Ti wear-resistant coatings for lightweight structural applications

Lightweight coatings based on titanium and titanium carbides produced by plasma spraying can be used to improve and modify the tribomechanical properties of aerospace structural materials. Although plasma-sprayed WC/Co coatings have been applied with success in many cases, such as primary wear-resistant materials, their high densities preclude their use in applications that mandate reduction in weight. In the present investigation, the sliding wear resistance of plasma-sprayed, metal-bonded TiC coatings on Al 7075 substrates was studied, Coatings containing 50, 70, and 90 vol% TiC in a Ti matrix produced from physically blended powders of Ti and TiC were compared. Metallographic evaluations showed that dense coatings with good bonding to Al 7075 substrates can be obtained. Coatings from commercial purity (CP) Ti powders sprayed in air under atmospheric conditions, however, indicated considerable oxidation of the particles. Under dry sliding conditions, the coefficient of friction (COF) values of the Ti/TiC containing/Al 7075 substrate system were lower than high-velocity oxygen fuel (HVOF) sprayed 75% Cr3C2/25%NiCr coatings on steel and were comparable to coatings of WC/Co, Vacuum plasma-sprayed TiC/Ti coatings with 90 vol% TiC also exhibited better wear resistance than HVOF sprayed 75%Cr3C2/25%NiCr.