Advanced HVOF-Sprayed Carbide Cermet Coatings as Environmentally Friendly Solutions for Tribological Applications: Research Progress and Current Limitations
Thermally sprayed carbide cermet coatings, particularly those based on tungsten carbide (WC) and chromium carbide (Cr<sub>3</sub>C<sub>2</sub>) and produced with the high velocity oxygen fuel (HVOF) process, are used in tribological applications as environmentally friendly al...
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MDPI AG
2025-07-01
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| Series: | Technologies |
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| Online Access: | https://www.mdpi.com/2227-7080/13/7/281 |
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| author | Basma Ben Difallah Yamina Mebdoua Chaker Serdani Mohamed Kharrat Maher Dammak |
| author_facet | Basma Ben Difallah Yamina Mebdoua Chaker Serdani Mohamed Kharrat Maher Dammak |
| author_sort | Basma Ben Difallah |
| collection | DOAJ |
| description | Thermally sprayed carbide cermet coatings, particularly those based on tungsten carbide (WC) and chromium carbide (Cr<sub>3</sub>C<sub>2</sub>) and produced with the high velocity oxygen fuel (HVOF) process, are used in tribological applications as environmentally friendly alternatives to electroplated hard chrome coatings. These functional coatings are especially prevalent in the automotive industry, offering excellent wear resistance. However, their mechanical and tribological performances are highly dependent on factors such as feedstock powders, spray parameters, and service conditions. This review aims to gain deeper insights into the above elements. It also outlines emerging advancements in HVOF technology—including in situ powder mixing, laser treatment, artificial intelligence integration, and the use of novel materials such as rare earth elements or transition metals—which can further enhance coating performance and broaden their applications to sectors such as the aerospace and hydro-machinery industries. Finally, this literature review focuses on process optimization and sustainability, including environmental and health impacts, critical material use, and operational limitations. It uses a life cycle assessment (LCA) as a tool for evaluating ecological performance and addresses current challenges such as exposure risks, process control constraints, and the push toward safer, more sustainable alternatives to traditional WC and Cr<sub>3</sub>C<sub>2</sub> cermet coatings. |
| format | Article |
| id | doaj-art-8cd16b1682ed4e99bc0c3699cb4e78ae |
| institution | Kabale University |
| issn | 2227-7080 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Technologies |
| spelling | doaj-art-8cd16b1682ed4e99bc0c3699cb4e78ae2025-08-20T03:56:47ZengMDPI AGTechnologies2227-70802025-07-0113728110.3390/technologies13070281Advanced HVOF-Sprayed Carbide Cermet Coatings as Environmentally Friendly Solutions for Tribological Applications: Research Progress and Current LimitationsBasma Ben Difallah0Yamina Mebdoua1Chaker Serdani2Mohamed Kharrat3Maher Dammak4Laboratory of Electromechanical Systems, National School of Engineers of Sfax, University of Sfax, Sfax 3038, TunisiaCenter for the Development of Advanced Technologies, Algiers 16081, AlgeriaCenter for the Development of Advanced Technologies, Algiers 16081, AlgeriaLaboratory of Electromechanical Systems, National School of Engineers of Sfax, University of Sfax, Sfax 3038, TunisiaLaboratory of Electromechanical Systems, National School of Engineers of Sfax, University of Sfax, Sfax 3038, TunisiaThermally sprayed carbide cermet coatings, particularly those based on tungsten carbide (WC) and chromium carbide (Cr<sub>3</sub>C<sub>2</sub>) and produced with the high velocity oxygen fuel (HVOF) process, are used in tribological applications as environmentally friendly alternatives to electroplated hard chrome coatings. These functional coatings are especially prevalent in the automotive industry, offering excellent wear resistance. However, their mechanical and tribological performances are highly dependent on factors such as feedstock powders, spray parameters, and service conditions. This review aims to gain deeper insights into the above elements. It also outlines emerging advancements in HVOF technology—including in situ powder mixing, laser treatment, artificial intelligence integration, and the use of novel materials such as rare earth elements or transition metals—which can further enhance coating performance and broaden their applications to sectors such as the aerospace and hydro-machinery industries. Finally, this literature review focuses on process optimization and sustainability, including environmental and health impacts, critical material use, and operational limitations. It uses a life cycle assessment (LCA) as a tool for evaluating ecological performance and addresses current challenges such as exposure risks, process control constraints, and the push toward safer, more sustainable alternatives to traditional WC and Cr<sub>3</sub>C<sub>2</sub> cermet coatings.https://www.mdpi.com/2227-7080/13/7/281thermal sprayHVOFWC cermet coatingsCr<sub>3</sub>C<sub>2</sub> cermet coatingsenvironmental concernstribology |
| spellingShingle | Basma Ben Difallah Yamina Mebdoua Chaker Serdani Mohamed Kharrat Maher Dammak Advanced HVOF-Sprayed Carbide Cermet Coatings as Environmentally Friendly Solutions for Tribological Applications: Research Progress and Current Limitations Technologies thermal spray HVOF WC cermet coatings Cr<sub>3</sub>C<sub>2</sub> cermet coatings environmental concerns tribology |
| title | Advanced HVOF-Sprayed Carbide Cermet Coatings as Environmentally Friendly Solutions for Tribological Applications: Research Progress and Current Limitations |
| title_full | Advanced HVOF-Sprayed Carbide Cermet Coatings as Environmentally Friendly Solutions for Tribological Applications: Research Progress and Current Limitations |
| title_fullStr | Advanced HVOF-Sprayed Carbide Cermet Coatings as Environmentally Friendly Solutions for Tribological Applications: Research Progress and Current Limitations |
| title_full_unstemmed | Advanced HVOF-Sprayed Carbide Cermet Coatings as Environmentally Friendly Solutions for Tribological Applications: Research Progress and Current Limitations |
| title_short | Advanced HVOF-Sprayed Carbide Cermet Coatings as Environmentally Friendly Solutions for Tribological Applications: Research Progress and Current Limitations |
| title_sort | advanced hvof sprayed carbide cermet coatings as environmentally friendly solutions for tribological applications research progress and current limitations |
| topic | thermal spray HVOF WC cermet coatings Cr<sub>3</sub>C<sub>2</sub> cermet coatings environmental concerns tribology |
| url | https://www.mdpi.com/2227-7080/13/7/281 |
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