In this study, the influence of plasma and detonation spraying techniques on the microstructure and wear behaviour of FeNiCrBSiC-20wt%CrB2 coating was investigated. The obtained coatings were found to comprise of Fe, Ni-based solid solution matrix reinforced with mixed boride phases (Fe,Cr)2B, (Ni,Fe,Cr)B, (Cr,Fe,Ni, Mo)B. The main microstructural differences of the plasma and detonation sprayed coatings are the morphology, the size and the distribution of hard boride particles. The tribological behaviour of coatings was examined under dry sliding conditions against Al2O3 ball at 20, 200 and 400 °C. The wear loss of detonation sprayed coatings was slightly lower at high temperatures while plasma sprayed coating had same wear at all temperatures. The investigation of worn surfaces revealed that abrasive and oxidative wear mechanisms are proved to be dominant for FeNiCrBSiC−20wt.%CrB2 plasma sprayed coatings, while brittle delamination and oxidative wear are characteristic for detonation sprayed coating. The sliding wear loss of the unreinforced commercial FeNiCrBSiC plasma sprayed coating was 2-3 times higher than that of reinforced (with chromium boride) coating at high temperatures due to splat delamination.
