Tribological components working at high temperatures and in aggressive environments are greatly required in advanced gas turbines, energy processing and power generation industries. To meet these application expectations, coatings with self-lubrication properties, exceptional high-temperature wear and oxidation resistance properties are a necessity. Thermally sprayed Cr3C2–NiCr coating is promising because of its very high hardness and oxidation resistance behavior up to 800 °C . BaF2•CaF2 eutectic and Cr3C2 powders which were coated with NiCr alloy were prepared by the hydrogen reduction hydrothermal process combined with a solid state alloying method to overcome the problems occurred in the plasma spray process. Then the processed NiCr/Cr3C2 and NiCr/BaF2•CaF2 particles were used as hard wear-resistant phase and high-temperature solid lubricant to prepare NiCr/Cr3C2–BaF2•CaF2 self-lubrication wear-resistant coating by plasma spray. NiCr alloy-coated powders are prepared by pressurized hydrogen reduction and solid state alloying process. These powders can reduce the decarburization of carbide, oxidation and ablation in plasma spray process, which leads to an improved quality of the derived coating. For example, the microstructure of plasma-sprayed NiCr/Cr3C2–BaF2•CaF2 coating was fine and densewith low porosity, high micro-hardness and cohesive strength.
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