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In this investigation, AISI 1020 low carbon steel has been selected as the base material. The Ni based super alloy powder NiCrBSiFeC was sprayed on the base material using high velocity oxy-fuel spraying (HVOF) technique. The thickness of the coating was approximately 0.5 mm (500 μm). The coating was characterized using optical microscopy, Vickers microhardness testing, X-ray diffraction technique and scanning electron microscopy. Dry sliding wear tests were carried out at 3 m / s sliding speed under the load of 10 N for 1000 m sliding distance at various temperatures i.e., 35  °   C, 250  °   C and 350  °   C. The corrosion test was carried out in 1 M copper chloride in acetic acid solution. The polarization studies were also conducted for both base material and coating. The improvement in microhardness from 1.72 GPa (175 HV  0.05 )  to 10.54 GPa (1075 HV  0.05  ) was observed. The coatings exhibited 3–6 times improved wear resistance as compared with base material. Also, the corrosion rate was reduced by 3.5 times due to the presence of coatings.

Improvement in wear and corrosion resistance of AISI 1020 steel by high velocity oxy-fuel spray coating containing Ni-Cr-B-Si-Fe-C