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The NiCr–TiB2–ZrB2 composite coating was deposited on the surface of blades made of steel (SUS304) using high-energy ball milling technology and air plasma spraying technology, which aimed to relieve the wear of the blades during operation. The influence of titanium diboride (TiB2) and zirconium diboride (ZrB2) on the microstructure and wear resistance of the coatings was investigated by X-ray diffraction, scanning electron microscopy, Vickers microhardness tester, and a wear tester. The results showed that the TiB2 and ZrB2 particles were unevenly distributed in the coatings and significantly increased the hardness and anti-wear, which contributed to their ultra-high hardness and extremely strong ability to resist deformation. The performance of the coatings was improved with the increase of the number of ceramic phases, while the hardness and wear resistance of the coating could reach their highest value when the TiB2 and ZrB2 respectively took up 15 wt.% of the total mass of the powder.

Composition versus Wear Behaviour of Air Plasma Sprayed NiCr–TiB2–ZrB2 Composite Coating