The tribological behavior of Ni-based coatings was analyzed. The coatings were deposited on grey cast iron substrates in a spray and fuse process using Superjet Eutalloy deposition equipment, varying the oxygen flow conditions in the flame. By means of the X-ray diffraction (XRD) technique, the crystal structure of the coatings was determined. The XRD patterns show the crystalline phases with principal reflections for Ni in the planes (111) and (222). Crystalline properties such as the orientation coefficient, crystallite size, and macrostrain showed the relationship with tribological and mechanical properties such as the dry wear rate and the microhardness. The microhardness was analyzed on the surface and on cross sections of the coatings by means of a Knoop microhardness tester. The topography and the morphological characteristics of the coatings and the tribo-surfaces were exanimated using scanning electron microscopy (SEM) and confocal microscopy, while the chemical composition was measured by means of energy-dispersive X-ray spectroscopy (EDS). The tribological behavior of the coatings was examined via the scratch cohesion–adhesion test, using cross sections of the coatings. Furthermore, adhesion and abrasion wear tests were carried out, using the pin-on-disk method, under the ASTM G99 standard and the ASTM G65 standard, respectively. The wear rate of the coatings showed a strong relation to the porosity in the metal matrix, which was previously determined via electrochemical characterization techniques.
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