Abstract
Self-fluxing Ni-based coatings (NiCrFeBSiC) were deposited through gas-flame spraying and evaluated in three conditions: as-sprayed, flame-remelted, and furnace-heat-treated (1025 °C/5 min). Phase analysis (XRD) revealed FeNi3 together with strengthening carbides/borides (e.g., Cr7C3, Fe23(C,B)6); post-treatments increased lattice order. Cross-sectional image analysis showed progressive densification (thickness ~805 → 625 → 597 µm) and a drop in porosity from 7.866% to 3.024% to 1.767%. Surface roughness decreased from Ra = 31.860 to 14.915 to 13.388 µm. Near-surface microhardness rose from 528.7 ± 2.3 to 771.6 ± 4.6 to 922.4 ± 5.7 HV, while adhesion strength (ASTM C633) improved from 18 to 27 to 34 MPa. Wettability followed the densification trend, with the contact angle increasing from 53.152° to 79.875° to 89.603°. Under dry ball-on-disk sliding against 100Cr6, the friction coefficient decreased and stabilized (0.648 ± 0.070 → 0.173 ± 0.050 → 0.138 ± 0.003), and the counterbody wear-scar area shrank by ~95.6% (0.889 → 0.479 → 0.0395 mm2). Wear-track morphology evolved from abrasive micro-cutting (as-sprayed) to reduced ploughing (flame-remelted) and a polishing-like regime with a thin tribo-film (furnace). Potentiodynamic tests indicated the lowest corrosion rate after furnace treatment (CR ≈ 0.005678 mm·year−1). Overall, furnace heat treatment provided the best structure–property balance (lowest porosity and Ra, highest HV and adhesion, lowest and most stable μ, and superior corrosion resistance) and is recommended to extend the service life of NiCrFeBSiC coatings under dry sliding.