Microstructure and properties of a wear resistant Al–25Si–4Cu–1Mg coating prepared by supersonic plasma spraying

A high content silicon aluminum alloy(Al–25Si–4 Cu–1Mg) coating was prepared on a 2A12 aluminum alloy by supersonic plasma spraying. The morphology and microstructure of the coating were observed and analyzed. The hardness, elastic modulus, and bonding strength of the coating were measured. The wear resistance of the coating and 2A12 aluminum alloy was studied by friction and wear test. The results indicated that the coating was compact and the porosity was only 1.5%. The phase of the coating was mainly composed of α-Al and β-Si as well as some hard particles(Al_9Si,Al_(3.21)Si_(0.47), and CuAl_2). The average microhardness of the coating was HV 242, which was greater than that of 2 A12 aluminum alloy(HV 110). The wear resistance of the coating was superior to 2A12 aluminum alloy. The wear mechanism of the 2A12 aluminum alloy was primarily adhesive wear, while that of the coating was primarily abrasive wear. Therefore, it is possible to prepare a high content silicon aluminum alloy coating with good wear resistance on an aluminum alloy by supersonic plasma spraying.     

放电等离子烧结制备石墨烯纳米片增强7075铝合金复合材料的力学性能

A 0.3wt% graphene nanoplatelets (GNPs) reinforced 7075 aluminum alloy matrix (7075 Al) composite was fabricated by spark plasma sintering and its strength and wear resistance were investigated. The microstructures of the internal structure, the friction surface, and the wear debris were characterized by scanning electron microscopy, X-ray diffraction, and Raman spectroscopy. Compared with the original 7075 aluminum alloy, the hardness and elastic modulus of the 7075 Al/GNPs composite were found to have increased by 29% and 36%, respectively. The results of tribological experiments indicated that the composite also exhibited a lower wear rate than the original 7075 aluminum alloy.     

Microstructure of Ni–Al powder and Ni–Al composite coatings prepared by twin-wire arc spraying

Ni–Al powder and Ni–Al composite coatings were fabricated by twin-wire arc spraying (TWAS). The microstructures of Ni-5wt%Al powder and Ni-20wt%Al powder were characterized by scanning electronic microscopy (SEM) and energy dispersive spectroscopy (EDS). The results showed that the obtained particle size ranged from 5 to 50 μm. The morphology of the Ni–Al powder showed that molten particles were composed of Ni solid solution, NiAl, Ni₃Al, Al₂O₃, and NiO. The Ni–Al phase and a small amount of Al₂O₃ particles changed the composition of the coating. The microstructures of the twin-wire-arc-sprayed Ni–Al composite coatings were characterized by SEM, EDS, X-ray diffraction (XRD), and transmission electron microscopy (TEM). The results showed that the main phase of the Ni-5wt%Al coating consisted of Ni solid solution and NiAl in addition to a small amount of Al₂O₃. The main phase of the Ni-20wt%Al coating mainly consisted of Ni solid solution, NiAl, and Ni₃Al in addition to a small amount of Al and Al₂O₃, and NiAl and Ni₃Al intermetallic compounds effectively further improved the final wear property of the coatings. TEM analysis indicated that fine spherical NiAl₃ precipitates and a Ni–Al–O amorphous phase formed in the matrix of the Ni solid solution in the original state.     

Microstructure and mechanical properties of twin-wire arc sprayed Ni-Al composite coatings on 6061-T6 aluminum alloy sheet

We have systematically studied the microstructure and mechanical properties of Ni-5wt%Al and Ni-20wt%Al composite coatings fabricated on 6061-T6 aluminum alloy sheet by twin-wire arc spraying under different experimental conditions. The abrasive wear behavior and interface diffusion behavior of the composite coatings were evaluated by dry/wet rubber wheel abrasive wear tests and heat treatment, respectively. Experimental results indicate that the composite coatings exhibit features of adhesive wear. Besides, the Vickers microhardness of NiAl and Ni₃Al intermetallic compounds is relatively larger than that of the substrate, which is beneficial for enhancing the wear resistance. With the increase of annealing temperature and time, the interface diffusion area between the Ni-Al coating and the substrate gradually expands with the formation of NiAl₃ and Ni₂Al₃ phases, and is controlled by diffusion of aluminum atoms. The grain growth exponent n of diffusion kinetics of the Ni-Al coating, calculated via a high-temperature diffusion model at 400, 480, and 550℃, is between 0.28 and 0.38. This satisfies the cubic law, which is consistent with the general theoretical relationship of high-temperature diffusion.     

Characterization of NbSi_2–Al_2O_3 nanocomposite coatings prepared with plasma spraying mechanically alloyed powders

The present study characterized NbS i2–Al2O3 nanocomposite powders plasma-sprayed on Ti–6Al–4Vsubstrates. The powders were agglomerated to obtain suitable particle sizes for spraying. The agglomerated powders were then plasma-sprayed using atmospheric plasma spraying. The structural transformations of the powders along with the morphological and mechanical changes of the coatings were examined by X-ray diffraction, scanning electron microscopy, energy dispersive spectroscopy, transmission electron microscopy, and hardness testing. The results showed that after plasma spraying, the grain size increased, and the lattice strain decreased. However, the grain size of this compound after spraying was still in the nanometer range. The coating was uniform and exhibited good adhesion to the substrate. The microhardness and fracture toughness of the nanocomposite coating were higher than those of a nanostructured NbS i2 coating.     

工艺参数对激光熔覆FeNiCoCrTi0.5高熵合金涂层组织和性能的影响

FeNiCoCrTi_0.5 coatings with different process parameters were fabricated by laser cladding. The macro-morphology, phase, microstructure, hardness, and wear resistance of each coating were studied. The smoothness and dilution rate of the FeNiCoCrTi_0.5 coating generally increased with the increase of specific energy (E_s), which is the laser irradiation energy received by a unit area. FeNiCoCrTi_0.5 coatings at different parameters had bcc, fcc, and Ti-rich phases as well as equiaxed, dendritic, and columnar structures. When E_s increased, the size of each structure increased and the distribution area of the columnar and dendritic structures changed. The prepared FeNiCoCrTi_0.5 coating with the E_s of 72.22 J·mm–2 had the highest hardness and the best wear resistance, the highest hardness of the coating reached HV 498.37, which is twice the substrate hardness. The average hardness of the FeNiCoCrTi_0.5 coating with the E_s of 72.22 J·mm–2 was 15.8% higher than the lowest average hardness of the coating with the E_s of 108.33 J·mm–2. The worn surface morphologies indicate that the FeNiCoCrTi_0.5 coatings exhibited abrasive wear.     

Effect of benzaldehyde on the electrodeposition and corrosion properties of Ni–W alloys

The effect of different concentrations of benzaldehyde on the electrodeposition of Ni–W alloy coatings on a mild steel substrate from a citrate electrolyte was investigated in this study. The electrolytic alkaline bath (pH 8.0) contained stoichiometric amounts of nickel sulfate, sodium tungstate, and trisodium citrate as precursors. The corrosion resistance of the Ni–W-alloy-coated specimens in 0.2 mol/L H₂SO₄ was studied using various electrochemical techniques. Tafel polarization studies reveal that the alloy coatings obtained from the bath containing 50 ppm benzaldehyde exhibit a protection efficiency of 95.33%. The corrosion rate also decreases by 21.5 times compared with that of the blank. A higher charge-transfer resistance of 1159.40 Ω·cm2 and a lower double-layer capacitance of 29.4 μF·cm-2 further confirm the better corrosion resistance of the alloy coating. X-ray diffraction studies reveal that the deposits on the mild steel surface are consisted of nanocrystals. A lower surface roughness value (R_max) of the deposits is confirmed by atomic force microscopy.     

High-temperature frictional wear behavior of MCrAlY-based coatings deposited by atmosphere plasma spraying

Al₂O₃-Cr₂O₃/NiCoCrAlYTa coatings were prepared via atmosphere plasma spraying (APS). The microstructure and phase composition of the coatings were analyzed by X-ray diffraction (XRD), scanning electron microscopy (SEM), laser confocal scanning microscopy (LSCM), and transmission electron microscopy (TEM). The dry frictional wear behavior of the coatings at 500℃ in static air was investigated and compared with that of 0Cr25Ni20 steel. The results show that the coatings comprise the slatted layers of oxide phases, unmelted particles, and pores. The hot abrasive resistance of the coatings is enhanced compared to that of 0Cr25Ni20, and their mass loss is approximately one-fifteenth that of 0Cr25Ni20 steel. The main wear failure mechanisms of the coatings are abrasive wear, fatigue wear, and adhesive wear.     

Microstructure and high-temperature wear properties of in situ TiC composite coatings by plasma transferred arc surface alloying on gray cast iron

In this work, an in situ synthesized TiC-reinforced metal matrix composite (MMC) coating of approximately 350–400μm thick-ness was fabricated on a gray cast iron (GCI) substrate by plasma transferred arc (PTA) surface alloying of Ti–Fe alloy powder. Microhard-ness tests showed that the surface hardness increased approximately four-fold after the alloying treatment. The microstructure of the MMC coating was mainly composed of residual austenite, acicular martensite, and eutectic ledeburite. Scanning electron microscopy (SEM) and X-ray diffraction analyzes revealed that the in situ TiC particles, which were formed by direct reaction of Ti with carbon originally contained in the GCI, was uniformly distributed at the boundary of residual austenite in the alloying zone. Pin-on-disc high-temperature wear tests were performed on samples both with and without the MMC coating at room temperature and at elevated temperatures (473 K and 623 K), and the wear behavior and mechanism were investigated. The results showed that, after the PTA alloying treatment, the wear resistance of the sam-ples improved significantly. On the basis of our analysis of the composite coatings by optical microscopy, SEM with energy-dispersive X-ray spectroscopy, and microhardness measurements, we attributed this improvement of wear resistance to the transformation of the microstruc-ture and to the presence of TiC particles.     

Microstructure and wear resistance of PTA clad Cr_7C_3/γ-Fe ceramal composite coating

A wear resistant Cr7C3/γ-Fe ceramal composite coating was fabricated on substrate of the hardening and tempering C degree steel by PTA (plasma transferred arc) cladding with (wt%) Fe-25Cr-7C elemental powder blends. Microstructure of the coating was characterized by OM, SEM, XRD and EDS. Wear resistance of the coating was tested under dry sliding wear condition at room temperature. The results indicate that the PTA clad ceramal composite coating has a rapidly solidified fine microstructure consisting of Cr7C3 primary particles uniformly distributed in theγ-Fe matrix and is metallurgically bonded to the C degree steel substrate. The PTA clad Cr7C3/γ-Fe ceramal composite coating has high hardness and excellent wear resistance under dry sliding wear test conditions. The excellent wear resistance of the Cr7C3/γ-Fe ceramal composite coating is attributed to the coating's high hardness, strong covalent atomic bonding and refined microstructure.     

HOT CORROSION OF A PLASMA SPRAYED CoNiCrAlTaSiY COATING

Hot corrosion(HC) of the APS(atomospheric plasma spraying)CoNiCrAlTaSiY coating on a nickel-base superalloy GH864 has been studied. The effect of laser-treatment on hot corrosion resistance was also examined.It was shown that CoNiCrAlTaSiY coating had superior properties in resistance to hot corrosion due to the readiness of the formation of a protective Cr₂O₃ scale on the coating surface.A model for the mechanism of hot corrosion of this coating has been suggested. Hot corrosion resistance of this coating was significantly increased by the laser treatment simply because the surface of the as sprayed coating was densified by the high power laser beam.     

Preparation and properties of the Ni-Al/Fe-Al intermetallics composite coating produced by plasma cladding

A novel approach to produce an intermetallic composite coating was put forward. The microstructure, microhardness, and dry-sliding wear behavior of the composite coating were investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectrum (EDS) analysis, microhardness test, and ball-on-disc wear experiment. XRD results indicate that some new phases FeAl, Fe_0.23Ni_0.77Al, and Ni₃Al exit in the composite coating with the Al₂O₃ addition. SEM results show that the coating is bonded with carbon steel metallurgically and exhibits typical rapid directional solidification structures. The Cr₇C₃ carbide and intermetallic compounds co-reinforced composite coating has a high average hardness and exhibits an excellent wear resistance under dry-sliding wear test compared with the Cr₇C₃ carbide-reinforced composite coating. The formation mechanism of the intermetallic compounds was also investigated.     

放电等离子烧结及热处理制备的Fe/316L/430–Ti(C,N)复合材料的滑动磨损行为

A series of novel steel–Ti(C,N) composites was fabricated by spark plasma sintering (SPS) and subsequent heat treatment. The hardness, indentation fracture resistance, and wear behaviour of the steel–Ti(C,N) composites were compared with those of the unreinforced samples, and their potentials were assessed by comparison with traditional cermet/hardmetal systems. The results showed that with the addition of 20wt% Ti(C,N), the wear rates of the newly examined composites reduced by a factor of about 2 to 4 and were comparable to those of cermets and hardmetals. The martensitic transformation of the steel matrix and the formation of in situ carbides induced by heat treatment enhanced the wear resistance. Although the presence of excessive in situ carbides improved the hardness, the low indentation fracture resistance (IFR) value resulted in brittle fracture, which in turn resulted in poor wear property. Moreover, the operative wear mechanisms were investigated. This study provides a practical and cost-effective approach to prepare steel–Ti(C,N) composites as potential wear-resistant materials.     

Abrasive resistance of metastable V–Cr–Mn–Ni spheroidal carbide cast irons using the factorial design method

Full factorial design was used to evaluate the two-body abrasive resistance of 3wt%C–4wt%Mn–1.5wt%Ni spheroidal carbide cast irons with varying vanadium (5.0wt%–10.0wt%) and chromium (up to 9.0wt%) contents. The alloys were quenched at 920℃. The regression equation of wear rate as a function of V and Cr contents was proposed. This regression equation shows that the wear rate decreases with increasing V content because of the growth of spheroidal VC carbide amount. Cr influences the overall response in a complex manner both by reducing the wear rate owing to eutectic carbides (M₇C₃) and by increasing the wear rate though stabilizing austenite to deformation-induced martensite transformation. This transformation is recognized as an important factor in increasing the abrasive response of the alloys. By analyzing the regression equation, the optimal content ranges are found to be 7.5wt%–10.0wt% for V and 2.5wt%–4.5wt% for Cr, which corresponds to the alloys containing 9vol%–15vol% spheroidal VC carbides, 8vol%–16vol% M₇C₃, and a metastable austenite/martensite matrix. The wear resistance is 1.9–2.3 times that of the traditional 12wt% V–13wt% Mn spheroidal carbide cast iron.     

Characterization and wear behavior of WC-0.8Co coating on cast steel rolls by electro-spark deposition

To prepare high wear resistance and high hardness coatings, electro-spark deposition was adopted for depositing an electrode of a mixture of 92wt%WC+8wt%Co on a cast steel roll substrate. The coating was characterized by classical X-ray diffractometer (XRD) and scanning electron microscopy (SEM) with energy dispersive X-ray analysis (EDX). The results indicate that the coating shows nanosized particulate structure and dendritic structure including columnar structure and equiaxed structure. The primary phases of the coating contain Fe₃W₃C, Co₃W₃C, Fe₂C and Si₂W. The coating has a low friction coefficient of 0.13, its average wear-resistance is 3.3 times that of the cast steel roll substrate and the main mechanism is abrasive wear. The maximum microhardness value of the coating is about 1573.9 Hv_0.3. The study reveals that the electro-spark deposition process has the characteristic of better coating quality and the coating has higher wear resistance and hardness.     

Corrosion-wear behavior of nanocrystalline Fe88Si12 alloy in acid and alkaline solutions

The corrosion-wear behavior of a nanocrystalline Fe₈₈Si₁₂ alloy disc coupled with a Si₃N₄ ball was investigated in acid (pH 3) and alkaline (pH 9) aqueous solutions. The dry wear was also measured for reference. The average friction coefficient of Fe₈₈Si₁₂ alloy in the pH 9 solution was approximately 0.2, which was lower than those observed for Fe₈₈Si₁₂ alloy in the pH 3 solution and in the case of dry wear. The fluctuation of the friction coefficient of samples subjected to the pH 9 solution also showed similar characteristics. The wear rate in the pH 9 solution slightly increased with increasing applied load. The wear rate was approximately one order of magnitude less than that in the pH 3 solution and was far lower than that in the case of dry wear, especially at high applied load. The wear traces of Fe₈₈Si₁₂ alloy under different wear conditions were examined and analyzed by scanning electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray photoelectron spectroscopy. The results indicated that the tribo-chemical reactions that involve oxidation of the worn surface and hydrolysis of the Si₃N₄ ball in the acid solution were restricted in the pH 9 aqueous solution. Thus, water lubrication can effectively improve the wear resistance of nanocrystalline Fe₈₈Si₁₂ alloy in the pH 9 aqueous solution.     

PTA clad (Cr,Fe)7C3/γ-Fe in situ ceramal composite coating

A wear-resistant (Cr, Fe)₇C₃/γ-Fe in situ ceramal composite coating was fabricated on the substrate of 0.45wt%C carbon steel by a plasma-transferred arc cladding process using the Fe-Cr-C elemental powder blends. The microstructure, microhardness, and dry-sliding wear resistance of the coating were evaluated. The results indicate that the microstructure of the coating, which was composed of (Cr, Fe)₇C₃ primary phase uniformly distributed in the γ-Fe, and the (Cr, Fe)₇C₃ eutectic matrix was metallurgically bonded to the 0.45wt%C carbon steel substrate. From substrate to coating, the microstructure of the coating exhibited an evident epitaxial growth character. The coating, indehiscent and tack-free, had high hardness and appropriate gradient. It had excellent wear resistance under the dry sliding wear test condition.     

Sliding wear behaviour of Fe/316L/430–Ti(C,N) composites prepared via spark plasma sintering and subsequent heat treatment

A series of novel steel–Ti(C,N) composites was fabricated by spark plasma sintering(SPS) and subsequent heat treatment. The hardness, indentation fracture resistance, and wear behaviour of the steel–Ti(C,N) composites were compared with those of the unreinforced samples, and their potentials were assessed by comparison with traditional cermet/hardmetal systems. The results showed that with the addition of 20 wt% Ti(C,N), the wear rates of the newly examined composites reduced by a factor of about 2 to 4 and were comparable to those of cermets and hardmetals. The martensitic transformation of the steel matrix and the formation of in situ carbides induced by heat treatment enhanced the wear resistance. Although the presence of excessive in situ carbides improved the hardness, the low indentation fracture resistance(IFR) value resulted in brittle fracture, which in turn resulted in poor wear property. Moreover, the operative wear mechanisms were investigated. This study provides a practical and cost-effective approach to prepare steel–Ti(C,N) composites as potential wear-resistant materials.     

Titanium carbonitride thick coating prepared by plasma spray synthesis and its tribological properties

TiCN coating, owing to its superior wear-resistance, has been frequently applied in many fields. TiCN thick coating was first prepared by reactive plasma spraying. The phase composition, microstructure and tribological properties of the TiCN coating were investigated in this research. Experimental results show that the microstructure of the TiCN coating was quite dense, and there was also a little amount of titanium oxides within the coating. By XPS analysis, Ti-C and Ti-N bonds were detected in the coating. The TiCN coating exhibited superior wear-resistance. The failure mechanism was attributed to the ad-hesive wear, the grinding of TiCN hard-grain, as well as the coating failure by oxidation. There were more Fe, Cr, O, etc. in the failure zone, suggesting that the corrosion propagated gradually from sur-face to interior.     

Evaluation of plasma sprayed YSZ thermal barrier coating with the CMAS deposits infiltrati on using impedance spectroscopy

The yttria-stabilized zirconi a (YSZ) thermal barri er coatings (TBCs) prepared by atmo-sp heric plasma spraying with different heat treatment period at the temperature of 1250°C were studied in the present investig ation. Electrochemical impedance spectroscopy (EIS) was employed to non-destructively examine the impedance and capaitance behavior of free standi ng YSZ coatings deposited by plasma spray with CMAS (calcium–magnesium–alumino-silicate) infiltration. Equivalent circuit was established on the basis of the biomodal structure in coatings. The sintering behavior of the coatings can be reflected by the changes of resistance and capacitance of the coating . By EIS , the microstructure evolution of the coating with CMAS deposits was discussed in detail.