Wear problem of grey cast irons selected as case study in this work is being faced in Brake Rotors, where abrasive and adhesive wear of these grey cast irons takes place due to the abrasive action. Although efforts have been made to reduce the friction coefficient and to increase the wear resistance of grey cast irons by varying alloying elements such as titanium yet there is little or no work on the use of coatings on various grades of grey cast irons used in braking rotors. The objective of the study is to develop the Detonation Sprayed wear resistant coatings Cylindrical pins of grey iron (GIHC and GI250) have been prepared. Three different coatings i.e. Stellite-21, Cr3C-25NiCr, and Al2O3-40TiO2 were deposited on end faces of these pins. Coatings were characterized using SEM/EDAX and XRD analysis. The wear testing on the uncoated as well as coated grey cast iron specimens was done with the help of Pin-on- Disk wear test rig. Wear data was collected for three loads i.e. 40N, 50N, 60N. The worn out specimens were characterized by SEM / EDXA analyses.
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