This study targets the issues of WC dissolution, grain coarsening, and the difficulty of simultaneously balancing wear and corrosion resistance in C276-based, WC-reinforced plasma arc cladded coatings. A Ti/B₄C multi-phase synergistic strengthening strategy was adopted, and a CFD–CA coupled model was used to quantitatively analyze the thermal–flow–solidification behavior in the 120–160 A current range, thereby determining a 140 A process window; accordingly, three coatings were prepared: W20 (C276 + 20 % WC), W20T (W20 + 10 % Ti), and W20TB (W20 + 5 % Ti + 5 % B₄C). The results show that the introduction of Ti generates in-situ TiC shells encapsulating the residual WC and dispersed TiC particles, which suppress WC dissolution and promote microstructural refinement; after further addition of B₄C, the solid solution of B and C lowers local misorientation (KAM). Compared with W20, the average microhardness of W20T and W20TB increases by about 1.2 times and 1.5 times, the wear volume rate decreases from 5.94 × 10−6 to 1.58 × 10−6 and 0.15 × 10−6 mm3·N−1·m−1, the friction coefficient drops from 0.54 to 0.23 and 0.21, and the corrosion resistance shows a slight decline, mainly due to micro-galvanic dissolution induced by Ti/C enrichment. The comprehensive strengthening mechanism derives from the pinning action of Ti/B/C solid-solution lattice distortion and dispersed precipitates on dislocations/grain boundaries, as well as the improvements brought by grain refinement and the increased proportion of high-angle grain boundaries. The study establishes a design pathway of “model-guided parameter selection—multiscale microstructural regulation—synergistic strengthening—performance trade-off,” providing a reference for the surface engineering of high-load, wear-service components of nickel-based alloys.
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