“Evaluation of Crystallite Sizes, Residual Stresses, Micro-XRF Spectroscopy, and Tribo-Corrosion Characteristics of Cermet Coatings using Synchrotron Radiation Techniques”

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PhD. Researcher Muhammad Tahir Farooq, s6609093960028@email.kmutnb.ac.th, The Sirindhorn International Thai-German Graduate School of Engineering (TGGS)  King Mongkut’s University of Technology North Bangkok; Professor (Associate) Dr. Peerawatt Nunthavarawong, peerawatt.n@tggs.kmutnb.ac.th, The Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut’s University of Technology North Bangkok (KMUTNB); Professor (Associate) Dr. Siriporn Daopiset, siriporn.d@tfii.kmutnb.ac.th, Thai-French Innovation Institute, King Mongkut's University of Technology North Bangkok, Bangkok Thailand; Dr. Abbas Mohimi, a.mohimi@twi.co.uk, NSIRC, TWI Ltd, Granta Park, Great Abington, Cambridge, UK; Dr. Chatree Saiyasombat, Synchrotron Light Research Institute, 111 University Avenue, Muang, Nakhon Ratchasima 30000, Thailand; 

This study assesses the structural, electrochemical, and tribological performance of HVOF-sprayed WC-10Co4Cr and Cr3C2-25NiCr cermet coatings on AISI 304 substrate, using Synchrotron radiation methods, micro-XRF spectroscopy, electrochemical, and the tribo-corrosion tests. Synchrotron XRD investigation of WC-10Co4Cr samples with crystallite diameters of 105 nm, 93 nm, and 86 nm revealed compressive residual stresses of -159 MPa, -287 MPa, and -351 MPa, confirming an inverse connection. In contrast, the diminished and overlapping Ni peaks in Cr3C2-25NiCr suggested amorphous phase growth due to rapid solidification, making residual stress difficult to estimate. Electrochemical testing (Tafel, EIS) showed corrosion rates of 4.395 mpy for bare steel, 1.329 mpy for Cr3C2-25NiCr, and 0.288 mpy for WC-10Co4Cr.  Tribo-corrosion studies in 0.05 M NaCl with a 3 N load at 1 Hz revealed that WC-10Co4Cr had the most stable open circuit potential -0.18V and the lowest coefficient of friction approximately 0.21   indicating strong passivation against mechanical wear. Micro-XRF examination revealed preferential Ni depletion in corroded and tribocorroded portions of Cr3C2-25NiCr, whereas WC-10Co4Cr retained elemental homogeneity.  These findings support the use of WC-10Co4Cr in hostile environments where durability and structural integrity are critical, as these demonstrate its superior resistance to corrosion, wear, and the tribo-corrosion degradation.

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March 2026

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