Evaluating Wear Performance of Plasma-Sprayed Chromia Coatings: Impact of Powder Feeding Rate and a Comparative Study with Ruby Coatings

Chromia coatings are widely recognized for their excellent wear and corrosion resistance, making them suitable for demanding applications in harsh environments. In this study, chromia coatings were deposited using high power plasma spraying with varying powder feeding rates to investigate the influence of this parameter on the coating's wear performance. The wear resistance of the coatings was evaluated through comprehensive wear test. In addition to the chromia coatings, plasma-sprayed ruby coatings were included for comparison to benchmark their wear behavior. Mechanical properties such as indentation fracture toughness and hardness were also assessed for deeper understanding of the coatings overall performance. Post wear analysis was done by analysing the wear track under SEM and measuring the surface roughness of the wear profile. This work provides valuable insights into optimizing the plasma spraying process for chromia coatings by adjusting the powder feeding rate and offers a comparative evaluation with ruby coatings, expanding the knowledge base on material selection for wear-resistant applications.