With the continuous advancement of modern technology, the application domains of mechanical equipment are expanding progressively, and their operational environments are becoming increasingly complex. This has led to the failure of metallic components due to high loads and severe wear, necessitating the development of new wear-resistant alloy materials with excellent comprehensive properties. Fe-Cr-Si-based alloys have emerged as promising candidates for various harsh working conditions due to their outstanding wear resistance, corrosion resistance, and high-temperature stability. However, the thermodynamic incompatibility between the D03 and A2 phases in the Fe-Cr-Si system results in relatively poor room-temperature wear resistance, limiting their practical applications. The addition of Co not only improves the microstructural stability and strength of the alloys but also increases the activity of carbon, thereby enhancing the nucleation driving force for carbides, accelerating their nucleation rate, and promoting carbide formation. This process refines the grain structure and enhances the hardness of the material. Against this backdrop, the work aims to investigate the effect of Co content on the microstructure, morphological characteristics, and tribological properties of Fe-Cr-Si alloys to improve their wear resistance under ambient conditions. Two series of FeCrSi-based alloys with varying Co contents, Fe18Cr10SixCo and Fe18Cr10Si4CxCo (x = 0, 1, 2, 3, 4) were prepared with an arc melting technique. The microstructures, microhardness, and wear performances of these alloys were systematically characterized through optical microscopy, scanning electron microscopy (SEM), microhardness testing, and friction-wear experiments. The results showed that the Fe18Cr10SixCo alloys exhibited a single-phase (Fe, Cr) solid solution structure. As the Co content increased, the microhardness of the alloys gradually increased, reaching a maximum of 349HV0.5 in the Fe18Cr10Si4Co alloy. However, both the friction coefficient and wear rate showed an upward trend with higher Co additions. The Fe18Cr10Si1Co alloy demonstrated the best wear resistance in this series, with a wear rate of 1.55× 10-4 g/m and a friction coefficient of 0.495 3. The dominant wear mechanisms transitioned from a combination of oxidative, adhesive, and abrasive wear to severe spalling wear and abrasive wear as the Co content increased, leading to a gradual decline in wear resistance. In contrast, the Fe18Cr10Si4CxCo alloys consisted of dendritic (Fe, Cr) solid solutions and interdendritic Cr-rich carbides (Cr7C3 and Cr3C2). With the increasing Co content, the formation of interdendritic carbides was promoted, resulting in a continuous increase in alloy hardness, peaking at 479HV0.5 for the Fe18Cr10Si4C4Co alloy. Concurrently, both the friction coefficient and wear rate decreased, with the Fe18Cr10Si4C4Co alloy exhibiting the best wear resistance (wear rate: 1.34×10-4 g/m; friction coefficient: 0.505 1). The wear mechanism in this series saw a deepening of oxidative wear, while adhesive and abrasive wear effects were relatively reduced. In conclusion, the addition of Co effectively promotes the formation of carbides in Fe18Cr10Si4CxCo alloys. Both the hardness and wear resistance of these alloys increase gradually with higher Co content, highlighting the crucial role of Co in optimizing the microstructure and tribological properties of Fe-Cr-Si-based materials for ambient applications. These findings provide valuable insights for the design and development of high-performance wear-resistant alloys in various industrial fields.
Key words
Fe-Cr-Si alloys /
Co content /
Cr-rich carbides /
microhardness /
wear resistance /
wear mechanism
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
References
[1] CHEN L Y, QIN P, ZHANG L N, et al.An Overview of Additively Manufactured Metal Matrix Composites: Preparation, Performance, and Challenge[J]. International Journal of Extreme Manufacturing, 2024, 6(5): 052006.
[2] DADKHAH M, MOSALLANEJAD M H, IULIANO L, et al.A Comprehensive Overview on the Latest Progress in the Additive Manufacturing of Metal Matrix Composites: Potential, Challenges, and Feasible Solutions[J]. Acta Metallurgica Sinica (English Letters), 2021, 34(9): 1173-1200.
[3] TANG J L, WANG K M, FU H G.Laser Cladding in Situ Carbide-Reinforced Iron-Based Alloy Coating: A Review[J]. Metals, 2024, 14(12): 1419.
[4] 黄海堂, 陈登华, 何曲波, 等. 铁基堆焊合金表面涂层耐磨性的研究进展[J]. 功能材料, 2023, 54(11): 11106-11117.
HUANG H T, CHEN D H, HE Q B, et al.Research Progress on Wear Resistance of Surface Coating on Iron-Based Surfacing Alloy[J]. Journal of Functional Materials, 2023, 54(11): 11106-11117.
[5] IDCZAK R, KONIECZNY R, PIKULA T, et al.Microstructure and Corrosion Properties of Fe-Cr-Si Alloys Prepared by Mechanical Alloying Method[J]. Corrosion, 2019, 75(6): 680-686.
[6] KIMURA M, SHIMIZU T, WATARI H.Fe-Cr-Si and Fe-Cr-Si-Mo Soft Magnetic Alloys Produced by MIM Process[J]. Journal of the Japan Society of Powder and Powder Metallurgy, 2023, 70(3): 160-167.
[7] QIN T Y, SONG C Y, MA R C, et al.Microstructure and Corrosion Resistance of Fe-Cr-Si Alloys[J]. Journal of Physics: Conference Series, 2021, 2101(1): 012077.
[8] 南雪丽, 周琦, 高海霞, 等. Fe3-xCrxSi合金在硫酸溶液中的耐蚀性能[J]. 兰州理工大学学报, 2011, 37(5): 14-17.
NAN X L, ZHOU Q, GAO H X, et al.Corrosion Resistance Performance of Alloys Fe3-xCrxSi in Sulfuric- Acid Solution[J]. Journal of Lanzhou University of Technology, 2011, 37(5): 14-17.
[9] 贵永亮, 张良, 王振磊, 等. Fe-Cr-Si系合金的研究现状与展望[J]. 材料导报, 2013, 27(S2): 343-345.
GUI Y L, ZHANG L, WANG Z L, et al.Research Progress and Development of Fe-Cr-Si Alloy[J]. Materials Review, 2013, 27(S2): 343-345.
[10] USUBA H, YAMAMOTO K, KIMURA Y, et al.Phase Equilibria and Microstructures in the Fe-Si-Cr-Ti System[J]. Intermetallics, 2006, 14(5): 505-507.
[11] DE ARAÚJO SOLER G, DE FARIA A O, BORGES J S, et al. Effect of Co Addition on the Microstructure and Mechanical Properties of an Al-2wt.%Ni Alloy[J]. Metals, 2024, 14(10): 1156.
[12] LIU W, LI S, PAN H C, et al.Development of Novel Mg-Al-Mn-Based Alloys with High-Strength and Ductility via Co-Addition of Ce and Ca[J]. Metals, 2025, 15(4): 361.
[13] YADAV A, JAIN V K, ATTATAPPA V, et al.Effect of Temperature and Co-Addition on Phase Stability, Magnetic and Electronic Properties of Fe2-xCoxMnAl Quaternary Heusler Alloys for Spintronics Devices[J]. Journal of Alloys and Compounds, 2025, 1027: 180579.
[14] NIKKHAH M R, GHEISARI K.Effect of Co Addition on the Structural Evolution and Magnetic Properties of Nanocrystalline Fe50Ni50-xCox Alloys Prepared by Mechanical Alloying[J]. Journal of Superconductivity and Novel Magnetism, 2023, 36(1): 315-325.
[15] ŁUKIEWSKA A, ŁUKIEWSKI M, HASIAK M, et al.Microstructure, Magnetic Properties, and Application of FINEMET-Type Alloys with Co Addition[J]. Applied Sciences, 2023, 13(8): 4693.
[16] YANG J Y, SONG W, WANG P, et al.A Novel High- Performance Co-Al-W-Based Superalloy for Additive Manufacturing[J]. Scripta Materialia, 2025, 266: 116771.
[17] 贺晓金, 张晋敏, 黄晋, 等. Co含量对Fe3 Si合金磁学性能的影响[J]. 计算物理, 2016, 33(6): 743-748.
HE X J, ZHANG J M, HUANG J, et al.Effect of Co Content on Magnetic Properties of Fe3 Si Alloy[J]. Chinese Journal of Computational Physics, 2016, 33(6): 743-748.
[18] 邓俊杰, 周健, 刘建雄, 等. Co对4Cr5Mo2V钢组织和强韧性的影响[J]. 金属热处理, 2021, 46(11): 48-53.
DENG J J, ZHOU J, LIU J X, et al.Effect of Co on Microstructure and Strength and Toughness of 4 Cr5Mo2V Steel[J]. Heat Treatment of Metals, 2021, 46(11): 48-53.
[19] 张国英, 曾梅光, 苏杰, 等. Co对高Ni-Co二次硬化钢微结构影响的穆斯堡尔谱研究[J]. 钢铁研究学报, 2001, 13(6): 35-39.
ZHANG G Y, ZENG M G, SU J, et al.Influence of Co on Microstructure of High Ni-Co Secondary Hardening Steel by Mossbauer Spectroscopy Study[J]. Journal of Iron and Steel Research, 2001, 13(6): 35-39.
[20] QUINTERO-ORTIZ J, GUERRA F V, BEDOLLA- JACUINDE A, et al.Sliding Wear Behavior of Co-Cr-Mo Alloys with C and B Additions for Wear Applications[J]. Wear, 2023, 522: 204698.
[21] YAN J H, SONG Z J, FANG W, et al.Composition Design of High Yield Strength Points in Single-Phase Co-Cr-Fe-Ni-Mo Multi-Principal Element Alloys System Based on Electronegativity, Thermodynamic Calculations, and Machine Learning[J]. Tungsten, 2023, 5(1): 169-178.
[22] TAMAYO A, RODRIGUEZ M A, RUBIO F, et al.Cobalt-Catalyzed Tunable Carbon Microstructures from Halogenated SiC Preceramic Precursors[J]. Journal of the American Ceramic Society, 2023, 106(1): 53-67.
[23] LIAO L H, LI J Y, ZHAO Z X, et al.Precipitation and Phase Transformation Behavior during High-Temperature Aging of a Cobalt Modified Fe-24Cr-(22-x)Ni-7Mo-xCo Superaustenitic Stainless Steel[J]. Journal of Materials Science, 2022, 57(7): 4771-4788.
[24] DONG L L, ZHOU J, GU J B, et al.Study on the Effect of Co Microalloying on the High-Temperature Tensile Behavior of 4Cr5Mo2V Hot Work Die Steel[J]. Steel Research International, 2025, 96(7): 2400819.
[25] SHI Q Y, DING X F, WANG M L, et al.Co Effect on As-Cast and Heat-Treated Microstructures in Ru-Containing Single-Crystal Superalloys[J]. Metallurgical and Materials Transactions A, 2014, 45(4): 1833-1843.
[26] MUKHERJI D, RÖSLER J. Co-Re-Based Alloys for High Temperature Applications: Design Considerations and Strengthening Mechanisms[J]. Journal of Physics: Conference Series, 2010, 240(1): 012066.
[27] SINGH M P, PANDEY P.Achieving Superior Strength and Low Mass Density in a Novel γ’ Strengthened CoNi-Based Superalloy[J]. Journal of Materials Science, 2025, 60(3): 1098-1115.
[28] LI B Y, ZOU P, WANG A Q, et al.Investigations on the Microstructure and Wear Properties of Ti2AlN Ceramic- Reinforced Titanium Alloy Composites Fabricated by Laser Powder-Directed Energy Deposition[J]. Surface and Coatings Technology, 2025, 502: 131986.
[29] ZHANG Y J, ZHAN H, WAN Q, et al.Multi-Objective Optimization of Process Parameters for Rectangular Laser Cladding of Fe-Based Alloy Wear-Resistant Coatings[J]. Surface and Coatings Technology, 2025, 503: 131990.
[30] FENG M Y, YANG X Z, LIAN G F, et al.Microstructure and Properties of Laser Cladding CoCrNi-Based Medium- Entropy Alloy Enhanced by Nb[J]. Journal of Materials Research and Technology, 2025, 35: 5015-5033.
Funding
Hebei Natural Science Foundation (E2024209149); Basic Research Operations of Provincial Colleges and Universities (JJC2024025); Science and Technology Program of Hebei (246Z1019G); Tangshan Science and Technology Programme (24130208C); Graduate Innovation Project of North China University of Science and Technology (2026B12)
PDF(24263 KB)
