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The use of powder-cored wires as electrodes for electrospark deposition (ESD) of coatings onto
quenched and low-tempered steel 45 was studied. An industrial PP-Np-PD80Kh20R3T powdercored
wire (PW) and a combined powder-cored wire with an MPG-7 graphite addition (PWG) were
applied. The mechanical characteristics peculiar to the surface layer of electrospark-deposited
coatings produced from the powder-cored wires (hardness HV, friction coefficient , elastic strain
energy Aelast, and plastic strain energy Aplast) were quantified. The indenter loading and kinetic
indentation depth curves were plotted. Variations in penetration depth Pd and recovery depth Rd of
the indenter in scratch tests of the ESD coatings produced from the powder-cored wires were
illustrated. Characteristic changes in the mechanical characteristics at a preset indenter penetration
depth and the microstructure of the ESD powder-cored coatings subjected to scratch tests were
examined. The wear rate of the ESD coatings deposited with PW and PWG electrodes was
established as a function of specific loading, sliding speed, and testing time. Variations in roughness
of the friction surfaces and temperatures in the contact area in dry sliding friction conditions were
studied. The PWG coating showed 24% higher hardness than the PW coating did and 10% lower
friction coefficient determined by indentation. The roughness of the PWG coating increased by 10%
when loading changed from 3 to 7 MPa. The PWG coating (pin-on-disk friction test) had 2.5 times
higher wear resistance than the PW coating did, and the disk (counterface) had 28% lower wear. A
slight increase of temperature in the tribological contact area was not found to soften the coating or
substrate (quenched and low-tempered steel 45) but promoted regeneration of the protective oxide
layer and favorably influenced the friction process. Both materials produced from the powder-cored
wires (PW and PWG) exhibited normal mechanochemical wear in experimental conditions. The high
wear resistance of the ESD coatings produced from the powder-cored wires in dry friction
conditions indicated that they would be beneficial for strengthening and improving the life of various
machine parts and mechanisms in industrial mechanical engineering.
