The study examines the microstructure and high-temperature properties of Cr₃C₂-25NiCr nanoceramic coatings on 316H high-temperature-resistant stainless steel that were prepared by high-velocity air–fuel spraying (HVAF) technology. The micromorphology, phase composition, fracture toughness, high-temperature hardness, high-temperature friction, and wear properties of the coating were studied by scanning electron microscopy (SEM), X-ray diffraction (XRD), high-temperature Vickers hardness tester, high-temperature friction and wear tester, and surface profiler. The results show that the Cr₃C₂-25NiCr coating prepared by HVAF presents a typical thermal spraying coating structure, with a dense structure and a porosity of only 0.34%. The coating consists of a Cr₃C₂ hard phase, a NiCr bonding phase, and a small amount of Cr₇C₃ phase; The average microhardness of the coating at room temperature is 998.8 HV_0.3, which is about five times higher than that of 316H substrate. The Weibull distribution of the coating is unimodal, showing stable mechanical properties. The average microhardness values of the coating at 450 °C, 550 °C, 650 °C, and 750 °C are 840 HV_0.3, 811 HV_0.3, 729 HV_0.3, and 696 HV_0.3 respectively. The average friction coefficient of the Cr₃C₂-25NiCr coating initially decreases and then increases with temperature. During high-temperature friction and wear, a dark gray oxide film forms on the coating surface. The formation speed of the oxide film accelerates with increasing temperature, shortening the running-in period of the coating. The oxide film acts as a lubricant, reducing the friction coefficient of the coating. The Cr₃C₂-25NiCr coating exhibits exceptional high-temperature friction and wear resistance, primarily through oxidative wear. The Cr₃C₂-25NiCr coating exhibits outstanding high-temperature friction and wear resistance, with oxidative wear being the primary wear mechanism at elevated temperatures.

This study examines the tribological and corrosion properties of Stellite 20 alloy coatings on F310H heat-resistant stainless steel that were prepared using HVOF and HVAF supersonic flame spraying techniques. To investigate the coatings’ microstructure, phase, microhardness, wear, and corrosion resistance, a range of characterization techniques, including SEM, EDS, XRD, microhardness, and friction wear-testers, weas employed. The results indicate that both HVOF and HVAF-prepared coatings exhibit a dense structure with porosity of 0.41% and 0.32%, respectively. The coatings are composed of γ-Co solid solution, ε-Co solid solution, Cr-rich solid solution, Cr₇C₃, WC, and CoCr₂O₄ phases. The microhardness of the Stellite 20 coatings prepared by HVOF and HVAF methods was 610 HV_0.3 and 690 HV_0.3, respectively, which is three times higher than that of the F310H stainless steel substrate. The wear mechanism of the HVAF coating is abrasive wear, while the wear mechanism of the HVOF coating is mainly fatigue wear with slight abrasive wear. The HVAF coating demonstrates superior wear resistance due to its higher flame velocity, denser coating, and higher average microhardness. In contrast, the HVOF coating shows a higher friction coefficient stability due to its lower hardness dispersion. The corrosion potentials of the HVOF and HVAF coatings are −0.532 V and −0.376 V, respectively, with corresponding corrosion current densities of 1.692 × 10⁻⁷ A·cm⁻² and 6.268 × 10⁻⁷ A·cm⁻², respectively. Compared to the HVOF coating, the Stellite 20 coating prepared using HVAF technology exhibits better wear and corrosion resistance.