A Review on Mechanical and Micro Structural Behaviour of Wear Resistant Coatings on Cast Iron

Abstract

Since it has good castability, comprehensive strength, toughness, and cheap production cost, ductile iron (DI) is widely used in many industrial applications, including machine tool beds, cams, valves, and cylinder blocks. However, its utility in certain sectors like mining and rolling industries is constrained by its low hardness and wear resistance under harsh service conditions. Due to insufficient pearlite content that can convert to martensite, traditional bulk or surface treatments such as flame surface hardening are ineffective in strengthening ferrite-matrix ductile iron. Rich in elements including vanadium, chromium, tungsten, and molybdenum, high-speed steel (HSS) coatings provide favourable characteristics on a DI substrate, such as excellent wear resistance, reliability, and hot hardness even at high temperatures. With the arrival of the fourth industrial revolution in the twenty-first century, the manufacturing and power generation sectors will grow to unprecedented heights. Higher operating plant/gas turbine temperatures and more reliable plants with fewer breakdowns are the main goals of engineers and researchers. The development of novel heat-, corrosion--, and erosion-resistant materials utilizing various surface engineering techniques has made this practically viable. This article's primary goal is to review the solid particle erosion behaviour of high entropy alloys, conventional materials, and nanomaterials at elevated temperatures. The summary analysis provided aids researchers in choosing the right composition, coating techniques, and erosion-resistant materials to fight erosion at these temperatures and prolong component life.