Arc Spraying of Nanostructured Wires on Steel Surfaces: Influence of Coating Thickness on Microstructure and Fracture Toughness

2012 ◽  
Vol 445 ◽  
pp. 803-808 ◽  
Author(s):  
A. Askandarani ◽  
M.S.J. Hashmi ◽  
Bekir Sami Yilbas
Keyword(s):  
Fracture Toughness ◽  
Coating Thickness ◽  
Spray Coating ◽  
Arc Spraying ◽  
Coating Materials ◽  
Noticeable Effect ◽  
Arc Spray ◽  
Carbon Steel Surface ◽  
Steel Surfaces ◽  
Spraying Process

nanostructured coating materials become demanding, since it improves the mechanical properties, such as hardness, through grain refinement. One of the methods of producing nanostructured coatings is to use an arc spray coating process using nanostructured wires. Although the arc spraying process is well developed, the influence of nanoparticles on the fracture toughness of the coating surface has not been examined in details. Consequently, in the present study, arc spraying of nanostructured wires on carbon steel surface is carried out. The influence of coating thickness on the microstructure and fracture toughness of the coating is investigated. It is found that the self-annealing due to large coating thicknesses has a noticeable effect on the microstructure and fracture toughness.

MECHANICAL PROPERTIES OF THERMAL ARC SPRAY ALUMINIUM COATING IN ATMOSPHERIC CONDITION

2015 ◽  
Vol 76 (10) ◽  
Author(s):  
Muhamad Hafiz Abd Malek ◽  
Nor Hayati Saad ◽  
Sunhaji Kiyai Abas ◽  
Noriyati Mohd Shah
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Corrosion Rate ◽  
Coating Thickness ◽  
Salt Spray ◽  
Atmospheric Condition ◽  
Spray Coating ◽  
Image Analyzer ◽  
Arc Spray ◽  
Two Samples

Thermal arc spray coating was regard as most preferred method as a protective coating due to its ability to sustain in high temperature, high friction surface, and low cost process. It has been applied by most of industrialist especially in oil and gas field, where current application of the coating used in onshore. This research is a study on mechanical properties of thermal arc spray coating by using aluminium alloy with purity 99.5% as coating material. Two samples with different coating thickness at range of 200 μm – 300 μm and 300 μm – 400 μm were used for this research. Some of tests were prepared to evaluate coating mechanical properties. Surface microstructures were viewed and analysed using scanning electron microscope and energy dispersive x-ray analysis.  The hardness was inspected using Vickers Hardness testing. Corrosion rate was established by performing Salt Spray Test. Porosity value was calculated using Image Analyzer. Surface roughness was viewed using Infinitefocus G4 machine. Experimental results were found that coating porosity was raising with enhancing of coating thickness. The increment coating thickness also resulted in reduction of hardness and surface roughness. For corrosion rate purpose, two samples with coating thickness at range of 200 μm – 300 μm and two samples with coating thickness at range 300 μm – 400 μm were prepared. It recorded at Rating 5 – Rating 7 after exposed in salt spray cabinet within 144 hours. As a result, coating thickness at range of 200 μm – 300 μm performs the most efficiency in terms of mechanical properties; less corrosion rate, less porosity and contribute to high hardness and surface roughness.  

scholarly journals Structure and Selected Properties of Arc Sprayed Coatings Containing In-Situ Fabricated Fe-Al Intermetallic Phases

Metals ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 1059 ◽  
Author(s):  
Tomasz Chmielewski ◽  
Piotr Siwek ◽  
Marcin Chmielewski ◽  
Anna Piątkowska ◽  
Agnieszka Grabias ◽  
...  
Keyword(s):  
Protective Coatings ◽  
Composite Coatings ◽  
Thermal Spraying ◽  
Intermetallic Phases ◽  
Arc Spraying ◽  
Coating Materials ◽  
Two Phases ◽  
Sprayed Coatings ◽  
Spraying Process

The paper presents the results of research on the production by means of arc spraying of composite coatings from the Fe-Al system with participation of in-situ intermetallic phases. The arc spraying process was carried out by simultaneously melting two different electrode wires, aluminum and steel. The aim of the research is to create protective coatings with a composite structure with a significant participation of FexAly as an intermetallic phases reinforcement. The synthesis of intermetallic phases takes place during the (in-situ) spraying process. Currently most coatings involving intermetallic phases are manufactured by different thermal spraying methods using coating materials in the form of prefabricated powders containing intermetallic phases. The obtained results showed the local occurrence of intermetallic phases from the Fe-Al system, and the dominant components of the structure have two phases, aluminum solid solutions in iron and iron in aluminum. The participation of intermetallic phases in the coating is relatively low, but its effect on the properties of the coating material is significant.

scholarly journals THE RESEARCH OF PSEUDO COATINGS SPRAYED WITH ELECTRIC ARC SPRAY / PSEUDODANGŲ, UŽPURKŠTŲ ELEKTROLANKINIU BŪDU, TYRIMAS

2017 ◽  
Vol 8 (6) ◽  
pp. 602-608
Author(s):  
Tomas Rodžianskas ◽  
Ovidijus Jarašiūnas ◽  
Irmantas Gedzevičius ◽  
Gediminas Mikalauskas ◽  
Justinas Gargasas ◽  
...  
Keyword(s):  
Power Source ◽  
Electric Arc ◽  
Arc Spraying ◽  
Main Task ◽  
Arc Spray ◽  
Tribological Coatings ◽  
Steel Aisi ◽  
Aisi 316 ◽  
Spraying Process ◽  
Stainless Steel Aisi

The paper presents coatings obtained using two different stainless steel (AISI 316) and marine bronze (CuAl8) wires sprayed with electric arc spraying. Substrate: mild steel S235J2 (LST EN 10025: 2004). Arc spray equipment – “EuTronic Arc Spray 4” with an additional power source. The main task was to select optimal technological spraying process and obtain coatings which possess the best mechanical, physical, tribological properties that meet the requirements of the specific requirements in service coatings. The microhardness, elastic modulus, and morphology was examined. Dry friction wear was assessed in the mass loss of the coatings. The results of tribological coatings properties were assessed in determining the mass lost. Straipsnyje nagrinėjamos elektrolankinio purškimo būdu suformuotos dangos, gautos užpurškus dvi skirtingas pilnavidurės nerūdijančiojo plieno (AISI 316) ir jūrinės bronzos (CuAl8) vielas. Substratas – mažaanglis plienas S235J2 (LST EN 10025:2004). Elektrolankinio purškimo įranga – „EuTronic Arc Spray 4“ su papildomu srovės šaltiniu. Eksperimentų metu siekiama parinkti optimalų technologinį purškimo procesą ir gauti dangas, pasižyminčias geriausiomis mechaninėmis, fizikinėmis, tribologinėmis savybėmis, kurios atitinka konkrečius keliamus reikalavimus eksploatuojamoms dangoms. Nustatytas dangų mikrokietumas, tamprumo modulis ir nagrinėta dangų morfologija. Dangų tribologiniai rezultatai vertinti nustatant prarastąją bandinių masę.

Microstructure and Corrosion Resistance of Fe-Based Coatings Prepared by Twin Wires Arc Spraying Process

2013 ◽  
Vol 23 (3) ◽  
pp. 333-339 ◽  
Author(s):  
Jinran Lin ◽  
Zehua Wang ◽  
Pinghua Lin ◽  
Jiangbo Cheng ◽  
Jingjing Zhang ◽  
...  
Keyword(s):  
Corrosion Resistance ◽  
Arc Spraying ◽  
Spraying Process

Non-Contact Coating Thickness Measurement

1998 ◽  
Author(s):  
P.E. Chandler ◽  
M.B.C. Quigley ◽  
J.F. Fletcher
Keyword(s):  
Coating Thickness ◽  
Thickness Measurement ◽  
Coating Structure ◽  
Line Measurement ◽  
Infra Red ◽  
On Line ◽  
Coating Thickness Measurement ◽  
Accuracy Of Measurement ◽  
Engine Components ◽  
Spraying Process

Abstract There are many instances of coatings that require a nondestructive and non-contact measure of coating thickness as part of a quality control system. Specifically, this paper reports on experiments carried out on non-contact measurements of MCrAIY and TBC coatings. The system uses an infra red beam from a solid state laser to generate a thermal wave in the coating. When this wave reaches the substrate an interference effect is caused. The modulated input heating produces a modulated output infra red signal from the surface and at a different wavelength from the laser beam. The output signal has a phase difference from the input signal which is related to the coating thickness. As neither the laser nor the detector are in contact with the surface of the coating and the temperature of the coating is raised by only a few degrees this represents a non-contact NDE system. This system has been tested across a range of coating/substrate combinations. In this paper we give examples of MCrAIY and TBC coatings applied to engine components demonstrating that the accuracy of measurement is only limited by the roughness of the coating structure and substrate. The use of this system for on-line measurement during the spraying process is also discussed and results presented.

Wear of Coated Cutting Tool Based on AdvantEdge

2014 ◽  
Vol 551 ◽  
pp. 221-227
Author(s):  
Zhi Qiang Zhang ◽  
Tie Qiang Gang ◽  
Yi Kai Yi
Keyword(s):  
Wear Rate ◽  
Coating Thickness ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Simulation Software ◽  
Machining Process ◽  
Sliding Velocity ◽  
Coating Materials ◽  
Element Simulation ◽  
Coated Tool

In this paper, based on finite element simulation software AdvantEdge, the effects of different coating materials and thickness on the wear of cutting tools during the machining process have been studied. For the tools with coating materials of TiAlN, Al2O3, TiN, TiC, we can calculate the wear rate according to the Usui mathematical model of tool wear, and then consider thickness factor of TiC coating. Because of the lowest thermal conductivity, the workpiece cut by TiC coated tool will soften first and more over cutting time, it result in the lowest wear rate. And with the increase of coating thickness, the effect of "thermal barrier" is more obvious for the relatively thicker coating tool, but the relative sliding velocity between the chip and tool is increasing meanwhile, so a suitable coating thickness is necessary.

Thermal Spray for Corrosion Control: A Competitive Edge for Commercial Shipbuilding

1995 ◽  
Vol 11 (01) ◽  
pp. 53-55
Author(s):  
Frank S. Rogers
Keyword(s):  
Thermal Spray ◽  
Marine Environment ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Cost Effective ◽  
Thermal Spray Coating ◽  
Coating System ◽  
Protection Mechanism ◽  
Arc Spray ◽  
Spray System

Thermal spraying of steel with aluminum to protect it from corrosion is a technology that has been proven to work in the marine environment. The thermal spray coating system includes a paint sealer that is applied over the thermally sprayed aluminum; this extends the service life of the coating, and provides color to the end product. The thermal spray system protects steel both through the principle of isolation (as in painting) and galvanization (as in galvanizing). With this dual protection mechanism, steel is protected from corrosion even when the coating is damaged. The thermal sprayed aluminum coating system has proven to be the most cost-effective corrosion protection system for the marine environment. Until recently, however, the initial cost of application has limited its use for general application. Today a new arc spray technology has reduced the application cost of thermal spraying aluminum to below that of painting. Commercial shipbuilders could use this technology to enhance their market position in the marine industry.

An Innovative Technique for Bi-Material Interface Toughness Research

2004 ◽  
Author(s):  
John Jy-An Wang ◽  
Ian G. Wright ◽  
Ken C. Liu ◽  
Roy L. Xu
Keyword(s):  
Thin Film ◽  
Fracture Toughness ◽  
Fracture Mechanics ◽  
Coefficient Of Thermal Expansion ◽  
Testing Procedure ◽  
Interface Fracture ◽  
Fracture Toughness Test ◽  
Coating Materials ◽  
Testing Procedures ◽  
Interface Fracture Toughness

A material configuration of central importance in microelectronics, optoelectronics, and thermal barrier coating technology is a thin film of one material deposited onto a substrate of a different material. Fabrication of such a structure inevitably gives rise to stress in the film due to lattice mismatch, differing coefficient of thermal expansion, chemical reactions, or other physical effects. Therefore, in general, the weakest link in this composite system often resides at the interface between the thin film and substrate. In order to make multi-layered electronic devices and structural composites with long-term reliability, the fracture behavior of the material interfaces must be known. Unfortunately, none of the state-of-the-art testing methods for evaluating interface fracture toughness is fully conformed to fracture mechanics theory, as is evident from the severe scatter in the existing data, and the procedure dependence in thin film/coating evaluation methods. This project is intended to address the problems associated with this deficiency and offers an innovative testing procedure for the determination of interface fracture toughness applicable to thin coating materials in general. Phase I of this new approach and the associated bi-material fracture mechanics development proposed for evaluating interface fracture toughness are described herein. The effort includes development of specimen configuration and related instrumentation set-up, testing procedures, and postmortem examination. A spiral notch torsion fracture toughness test (SNTT) system was utilized. The objectives of the testing procedure described are to enable the development of new coating materials by providing a reliable method for use in assessing their performance.

THE EFFECT OF COATING THICKNESS ON FATIGUE PROPERTIES OF STEEL THERMALLY SPRAYED WITH Ni-BASED SELF-FLUXING ALLOY

2006 ◽  
Vol 20 (25n27) ◽  
pp. 3599-3604 ◽  
Author(s):  
HIROYUKI AKEBONO ◽  
JUN KOMOTORI ◽  
HIDETO SUZUKI
Keyword(s):  
Fatigue Strength ◽  
Thermal Spray ◽  
Coating Thickness ◽  
Volume Fraction ◽  
Steel Substrate ◽  
Fatigue Cracks ◽  
Spray Coating ◽  
Maximum Size ◽  
Thermal Spray Coating ◽  
Fatigue Properties

The Thermal spraying is one of the most popular surface coating techniques. To achieve the most efficient use of this technique in practice, it is very important to clarify the fatigue properties of steel coated with a thermal spray coating. In this study, to clarify the effects of coating thickness on the fatigue properties of the steel substrate, three types of sprayed specimens with different coating thickness (0.2, 0.5 and 1.0mm) were prepared and fatigue tests were carried out. Coating thickness strongly affected the fatigue properties; the thinner the coating thickness, the higher the fatigue strength. Fatigue crack propagation behaviors were observed. Accordingly the fatigue cracks propagated through many defects on the coated surface. The sizes and number of the coating defects were determined by coating thickness; the thicker the coating thickness, the larger the defect and number. Therefore, the sprayed specimens with thinner coatings indicated higher fatigue strength. Furthermore, estimations of the fatigue strength were performed by using Murakami's equation. The fatigue strengths of thermal spray coated specimens were estimated by three parameters; (i) maximum size of coating defects estimated by statistics of extreme value, (ii) hardness of the matrix and (iii) volume fraction of coating defects.

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