Optimization of Thermal Spray Parameters of NiAl/Cr2C3 Coating by Taguchi Method

2019 ◽  
Vol 295 ◽  
pp. 9-14 ◽  
Author(s):  
M. Tahari ◽  
B. Luo ◽  
J. Geng ◽  
D. Jing ◽  
M. Hatami
Keyword(s):  
Wear Resistance ◽  
Thermal Spray ◽  
Feed Rate ◽  
Spray Coating ◽  
Wear Test ◽  
Thermal Spray Coating ◽  
Spray Parameters ◽  
Spray Distance ◽  
Powder Feed Rate ◽  
Powder Feed

In this study the effect of thermal spray process on wear resistance of NiAl/Cr2C3 thermal spray coating has been investigated. For this purpose the NiAl power mixed with 10 %wt. Cr2C3 powder and milled for 1 hrs at argon atmosphere. The APS parameters such as voltage (V), current (A), spray distance (mm), powder feed rate (gr/min), were optimize using a response surface methodology. For investigation effect of spray parameters on quality of coatings, the porosity and wear resistance of coatings analyzed with SEM and pin on disk wear test. Results show that increase of voltage and current are more effective other parameters. Increasing of powder feed rate and spray distance raised porosity of coatings intensively.

Observation of damage behavior with spray distance for Al-Zn-Zr thermal spray coating

2012 ◽  
Vol 44 (11-12) ◽  
pp. 1393-1396 ◽  
Author(s):  
Seong-Jong Kim ◽  
Seok-Ki Jang ◽  
Seung-Jun Lee
Keyword(s):  
Thermal Spray ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Spray Distance ◽  
Damage Behavior

Elasticity Characteristics of Plasma Spray Coatings

1996 ◽  
Author(s):  
L. Dekhtyar ◽  
A. Kleyman ◽  
S. Berman ◽  
V. Andreychuk
Keyword(s):  
Residual Stresses ◽  
Thermal Spray ◽  
Coating Thickness ◽  
Quantitative Methods ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Spray Parameters ◽  
Spray Coatings ◽  
Real Value ◽  
Elastic Characteristics

Abstract Future development of thermal spray processes and new composite materials raises an important problem concerning the transition from qualitative to quantitative methods of coatings evaluation. It is well known that thermal spray coating deposition in most cases is accompanied by the formation of temporal and residual stresses through the coating thickness. For proper evaluation of formed stressed state it is extremely important to know the real value of elastic characteristics in different layers of the coating. This problem has become more complicated taking into consideration the variety of materials, different spray parameters, number of coating layers and extreme service conditions. These values can be obtained only from experimentation. Elastic characteristics (EC) could be used in many calculations, such as durability, stiffness, fatigue, vibration and others. This paper describes new methods of experimental determination of elastic characteristics presumed as variable throughout the coating thickness. Influence of coating composition, particle size of initial powders, spray parameters, post-treatment and other factors on elastic modulusses were studied. Obtained experimental data for different materials supplement existing data and can be used for evaluation of residual stresses and other purposes.

Tribo Mechanical Properties of CoCr and NiWCrB Hardfacing Superalloy Coating Systems

2014 ◽  
Author(s):  
M. Azzi ◽  
L. Vernhes ◽  
E. Bousser ◽  
J. E. Klemberg-Sapieha
Keyword(s):  
Wear Resistance ◽  
Thermal Spray ◽  
Microstructural Analysis ◽  
Spray Coating ◽  
High Hardness ◽  
Thermal Spray Coating ◽  
Hard Coatings ◽  
Corrosion Properties ◽  
Cross Sectional ◽  
Indentation Technique

Wear of materials is a serious problem facing industry especially in mechanical applications where moving parts are continuously subjected to friction. Hard coatings prepared by a variety of processes are nowadays considered as effective solutions to protect components against wear. Examples of such processes are: thermal spray coating, vacuum-based coating and hardfacing. In this paper, we study the mechanical, tribological and corrosion properties of two hard coating systems: CoCr Stellite 6 (ST6) hardfacing on 316 stainless steel and NiWCrB Colmonoy 88 (C88) thermal spray coating on Inconel 718. The effect of gas nitriding on the microstructure and wear performance of these coating systems is investigated. X-ray diffraction, energy dispersive spectroscopy and scanning electron microscopy were used for microstructural analysis. Micro-indentation technique was utilized to measure the surface and cross-sectional hardness of the coatings. Rockwell indentation technique was used to evaluate coating adhesion in accordance with CEN/TS 1071-8. Pin-on-disk tests were conducted to assess the tribological performance of the coatings. Microstructural analysis showed that ST6 has a cobalt matrix in the form of dendrites reinforced with metal carbide particles whereas C88 has a Nickel matrix reinforced mainly with metal boride particles. ST6 and C88 improved significantly the wear resistance of their corresponding substrates. This is mainly due to good adhesion and high hardness of the coatings; HR15N values of ST6 and C88 were almost 85 as compared to 61 and 80 for 316 and INC substrates, respectively. ST6 was found to improve significantly the corrosion resistance of 316 whereas C88 decreased the corrosion performance of INC. Moreover, nitriding treatment was found to improve significantly the wear resistance of 316 and INC, however, in the case of ST6, nitriding was beneficial in terms of wear resistance only at relatively low load.

Optimizating Spray Parameters of High Velocity Oxy Fuel (HVOF) for Cr3C2 - NiCr Coating

2019 ◽  
Vol 889 ◽  
pp. 168-176
Author(s):  
Văn Chien Dinh ◽  
Thanh Phu Nguyen ◽  
Thanh Hoa Doan ◽  
Van Khoa Bui
Keyword(s):  
High Performance ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Spray Parameters ◽  
Optimal Parameters ◽  
Coating Properties ◽  
Powder Feed Rate ◽  
Hvof Spray ◽  
High Performance Coating ◽  
40Cr Steel

Porosity, hardness, and adhesion mainly affect the performance of thermal spray coating and significantly depend on spray parameters. Therefore, determining value of the spray parameters and their effects on the coating properties are always taken into consideration. This paper studies optimization as well as evaluates influences of HVOF spray parameters which include powder feed rate (M), rotational speed of the details per minute (N) and step movement of the nozzle per revolution (S) to the adhesion, porosity, micro-hardness of Cr3C2 - 20(80Ni20Cr) coating on 40Cr steel shaft substrate. Taguchi experimental design L9 combined with analysis of variance (ANOVA) was used to determine optimum spray parameters and percentage of effect of each spray parameter on properties of the coating. From obtained results, the optimal spray parameters are m = 35 g.min-1, n = 130 rpm, S = 6 mm for the highest hardness coating of 658.2 HV; with m = 45g.min-1, n = 130rpm, S = 3 mm for the smallest porosity of 1.27%; with m = 35g.min-1, n = 130 rpm, S = 3 mm for the coating with a maximum adhesion of 44.07 MPa. The percent effects of the parameters m, n, S to adhesion, porosity and hardness were (2.8%, 33.6%, 63.6%), (0.1%, 1.3%, 98.6%), (32.7%, 43.3%, 24%), respectively. The percent effects of spray parameters on corresponding coating property allows adjustment of spray parameters to obtain the desired coating. Verified experiment results shows that the results are reliable. Taguchi method and ANOVA can find optimal parameters of the HVOF spray to acquire high-performance coating.

Effects of Al2O3-13% TiO2 Coating Particle Size on Commercial Mild Steel via Plasma Spray Method

2011 ◽  
Vol 462-463 ◽  
pp. 645-650 ◽  
Author(s):  
Nik Hassanuddin ◽  
Mariyam Jameelah Ghazali ◽  
Andanastuti Muchtar ◽  
M.C. Isa ◽  
Abdul Razak Daud
Keyword(s):  
Surface Roughness ◽  
Plasma Spray ◽  
Feed Rate ◽  
Gas Pressure ◽  
The Other ◽  
Spray Parameters ◽  
Strengthening Effect ◽  
Powder Feed Rate ◽  
Carrier Gas ◽  
Powder Feed

This paper discusses the effect of Al2O3-13% TiO2 agglomerated nanoparticle powders ranging from 20 to 60 m and microparticle powders ranging from 10 to 25 m on commercial marine grade mild steels using a plasma spray technique. Prior to coating, the nanoparticle powders were subjected to a 2 level factorial design of experiment to give a careful control and optimise the operational spray parameters as well as process by using the statistical methods. The method was focused on the primary gas pressure, carrier gas pressure and powder feed rate of the spray parameters. The optimum properties of wear rate, surface roughness and microhardness were identified by using the lowest primary and carrier gas pressure together with the highest powder feed rate. As for the microparticle powders, they were subjected to an optimum properties by using 35 kW plasma spray power. In this study, the plasma spray power for microparticle varied from 20 kW to 40 kW, while the other parameters such as primary gas pressure, carrier gas pressure, powder feed rate and spray distance were held constant. It was found that microparticle powders exhibited denser coating microstructure s and improved both surface roughness and microhardness. On the other hand, the nanoparticle powder coating gave a greater wear resistance than those of micro particle powders, which may likely due to the strengthening effect of both fully and partially melted region.

scholarly journals Microstructure and Sliding Wear Resistance of Plasma Sprayed Al2O3-Cr2O3-TiO2 Ternary Coatings from Blends of Single Oxides

Coatings ◽  
2020 ◽  
Vol 10 (1) ◽  
pp. 42 ◽  
Author(s):  
Maximilian Grimm ◽  
Susan Conze ◽  
Lutz-Michael Berger ◽  
Gerd Paczkowski ◽  
Thomas Lindner ◽  
...  
Keyword(s):  
Wear Resistance ◽  
Sliding Wear ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Corrosion And Wear ◽  
Atmospheric Plasma ◽  
Spray Parameters ◽  
Oxide Materials ◽  
Spray Process ◽  
Plasma Sprayed

Al2O3, Cr2O3, and TiO2 are most commonly used oxide materials for thermal spray coating solutions. Each oxide shows unique properties comprising behavior in the spray process, hardness, corrosion, and wear resistance. In order to exploit the different advantages, binary compositions are often used, while ternary compositions are not studied yet. Atmospheric plasma spraying (APS) of ternary compositions in the Al2O3-Cr2O3-TiO2 system was studied using blends of plain powders with different ratios and identical spray parameters. Coatings from the plain oxides were studied for comparison. For these powder blends, different deposition rates were observed. The microstructure, roughness, porosity, hardness, and wear resistance were investigated. The formation of the splats from particles of each oxide occurs separately, without interaction between the particles. The exception are the chromium oxide splats, which contained some amounts of titanium. The predominant oxide present in each blend has a decisive influence on the properties of the coatings. While TiOx causes a low coating porosity, the wear resistance can be increased by adding Cr2O3.

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