Microstructure and Wear Resistance of Plasma-Sprayed Molybdenum Coating Reinforced by MoSi2 Particles

Mo coatings with or without incorporated MoSi2 were fabricated by atmospheric plasma spraying, and their microstructure, microhardness, bond strength, and wear resistance were compared. Two kinds of spray powder, i.e., pure Mo and a blend of Mo and MoSi2, were sprayed onto low-carbon steel. Microstructural analysis of the MoSi2-Mo coating showed MoSi2 homogeneously distributed in a Mo matrix. Addition of MoSi2 particles increased the microhardness of the as-sprayed Mo coating. The adhesion strength of the Mo coating was better than that of the MoSi2-Mo coating. Wear test results showed that the wear rate and friction coefficient of the two coatings increased with increasing load, and the friction coefficient of the MoSi2-Mo coating was lower than that of the Mo coating. The MoSi2-Mo composite coating exhibited better wear resistance than the Mo coating. The wear failure mechanisms of the two coatings were local plastic deformation, delamination, oxidation, and adhesion wear.