- Email: [email protected]
Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review
Materials Today: Proceedings xxx (xxxx) xxx
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review G. Padmavathi a,⇑, B.N. Sarada b, S.P. Shanmuganathan a, B.V. Padmini c, N. Mohan d a
Dayananda Sagar College of Engineering, Bangalore, Karnataka 560078, India BMS College of Engineering, Bangalore, Karnataka 560080, India c Sambhram Institute of Technology, Bangalore, Karnataka 560004, India d Dr. Ambedkar Institute of Technology, Bangalore, Karnataka 560056, India b
a r t i c l e
i n f o
Article history: Received 1 August 2019 Accepted 17 September 2019 Available online xxxx Keywords: Corrosion HVOF coating Fatigue Wear Microhardness
a b s t r a c t Chromium has excellent wear and corrosion properties with good lubrication and chemical resistance mainly used for decorative and practical applications. Nevertheless, the necessity to recognize replacements or to enhance the mechanical characteristics of chromium electroplating is of paramount importance mainly to overcome the environmental pollution and to enhance the fatigue strength of the substrate. The main reason for chromium coatings is to improve wear and corrosion properties of the component. But the main byproduct of this process is Cr + 6 (hexavalent chromium), that is hazardous to wellbeing of the surroundings. High Velocity Oxygen Fuel thermal spray coating (HVOF) is developed as an exceptional replacement for conventional hard chromium electroplating process. HVOF coatings possess improved hardness, wear and fatigue resistance in contrast to hard chromium coatings. An attempt has been made to conduct a survey to analyze the result of mechanical and tribological characteristics of HVOF coatings. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.
1. Introduction
1.1. HVOF - thermal coating system
Thermal spraying is a process of depositing metallic and nonmetallic materials either in liquefied or semi-liquefied state on the surface of the substrate that aids in providing excellent resistance to wear, erosion and corrosion [1]. The coating by thermal spray technique involves melting of material by application of electrical arc or combustible gas followed by atomization which is initiated due to kinetic energy of the gas stream and deposited onto the substrate. After the collision of the particles, it flattens and adheres to the surface complying with the geometry of the component. Finally adhered and surface leveled particles build up to constitute the coating. High strength materials are usually coated to resist the degeneration of the surface. Coating by thermal spray technology finds relevancy in Aerospace, Automobile, Textile and Mining sectors owing to superior binding strength, lower porosity and improved hardness [2].
A chemical mixture of oxygen and fuel (kerosene) undergoes atomization as it passes through the combustion chamber. During the process a jet of stream is generated. Combinations of alloys in powder form are introduced into the stream, which is melted, atomized and forced towards the surface at very high velocity. The exertion of kinetic and thermal energy to the particles creates an effective bonding on the substrate as shown in Fig. 1. HVOF coatings possessing zero porosity, high density and hardness finds suitable applications in corrosive environments. It has very good resistance to wear, extreme heat and abrasion. HVOF coated materials are scratch proof and are bound to the base metal at strengths more than 10,000PSI by satisfying environmental/ safety standards.
⇑ Corresponding author. E-mail address: [email protected] (G. Padmavathi).
2. Mechanical properties The important mechanical properties like hardness, density, fatigue strength and corrosion resistance were studied on various coating compositions.
https://doi.org/10.1016/j.matpr.2019.09.085 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
2
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 1. Working principle of HVOF [2].
L.F.S Vieria et al. [3], The fatigue property was evaluated using shot peening method. Fractured Ni based coated AISI 4340 steel specimens were analyzed using SEM. It was inferred that spray coated specimen exhibited improved property compared to uncoated component. R.G. Bonora et al [4], compared the outcome of tungsten carbide coating done by HVOF and conventional chromium electroplating on AISI 4340 steel on fatigue behaviour. The initiation of crack growth and adherence of the coating to the substrate were observed under SEM and Optical microscopy. The results showed excellent resistance to fatigue, surface degradation and wear behaviour when compared to plating by hard chromium. Manjunatha M et al [5], used Air Jet Erosion Tester to predict the influence of Cr3C2based coatings on erosive behavior of AISI 316 Molybdenum steel. Micro Vickers Hardness and XRD analysis is used to characterize the coated samples. Their experimental results revealed that HVOF sprayed Cr3C2/NiC (85/15) % coatings showed excellent corrosion and oxidation resistance. D. Deesom et al [6], NiCr powder and different weight percentage of CNTs [0, 0.5, 1] were ball milled and CVD process is employed for developing carbon nanotubes on NiCr powder. The main observation is Vickers hardness of NiCr-CNT is 20% enhanced when compared to pure NiCr coating.
N. Jegadeeswaran et al. [7], Carried out test in salt bath environment under hot corrosion condition at 800 °C by introducing the alloy specimens Ti-31 in as-is and uncoated condition. Chromium content is more pronounced in HVOF based coating and this provides the base alloy a barrier to high temperature corrosion, shown in Fig. 2. G. S. Junior and H. J. C. Voorwald et al. [8,24], inferred that shot peening effect results in complete transformation of compressive to tensile stresses and thereby subsequent reduction in residual stresses. Scanning electron microscope is used to study crack initiation points on the fractured fatigue specimens. Fatigue limit improved by 13.3% from 750 MPa to 850 MPa. Cheng Hung Yeh et al. [9], they employed HVOF and APS methods to study the mechanical properties on Nickel-Aluminum coatings at high temperature atmosphere up to 2950c. Finally, they revealed the Young’s modulus of the specimens coated with HVOF method is higher than APS method. Nagaraja C. Reddy et al. [10], coated Ni based powder on AISI 420 stainless steel and titanium alloy by HVOF technique. Micro hardness and microstructure were examined. Both Ni3Ti and Ni3Ti+(Cr3C2 + 20NiCr) coated specimens have higher micro hardness compared to substrate materials. NiO and Cr2O3 phases developed on outer surface of coatings were found useful to hamper oxidation rate at elevated temperatures.
Fig. 3. Thermal cycling lifetime of as-sprayed, grit-blasted, shot peening, and vacuum treatment TBCs [14].
Fig. 2. SEM results of samples under hot corrosion (i)Uncoated Ti-31 (ii) Coated Ti-31 [7].
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 4. Optical micrograph of a substrate (S)–deposit (D) interface of a sample after fatigue testing [18].
Fig. 5. Stress–strain curves of coated and uncoated specimens [22].
Fig. 6. S–N curves for axial fatigue tests [26].
L. Hernandez and F. Oliveira et al. [11,15], varied the settings like uncoated, grit blasting with alumina particles, grit blasted and deposited with Colmonoy 88 using HVOF method on AISI
3
4340 steel to observe the corrosion and fatigue properties. They revealed that, resistance to the stress applied and fatigue property is improved with HVOF deposition. The corrosion life of steel coated with Colmonoy deposit is increased extensively. M. P. Nascimento et al. [12], compared the performance of WC thermal sprayed HVOF process with electroplating technique. The fatigue strength exhibited by coated specimen is more compared to electroplated specimen. AISI 4340 steel showed rising trend in fatigue strength because of shot peening process. Maximum delamination is observed at the interface between shot peened specimen and electro-less nickel under layer. H. J. C. Voorwald et al. [13], reported the influence of WC based coatings on the fatigue resistance of AISI 4340 steel deposited by HVOF process in contrast to chromium electroplating, with and without shot peening process. It was observed that, Tungsten carbide coated specimens exhibits improved fatigue strength when related to chromium electroplating. Experimental results revealed WC-10Co-4Cr HVOF coated samples have improved axial fatigue and corrosion resistance when compared with WC-17Co samples in salt fog exposure. Liyong Ni et al. [14], examined the outcomes of surface modification on thermal cycling lifetime using different process like grit blasting, vacuum treatment and shot peening methods. They revealed that, the enhancement of thermal life of coating post surface modification is due to the formation of uniform and continuous development of Aluminum oxide as shown in Fig. 3. Li-Yong Ni et al. [16], analyzed HVOF coating on Ni based alloy (NiCrAlY) for Isothermal oxidation characteristics carried out at 1050 °C. The primary formation is Aluminum Oxide but combination of Al2O3 and NiCr2O4 are developed on coatings subjected to grit-blasting and shot peening methods. Buqian Wang et al. [17], characterized the erosion-corrosion property of HVOF coated NiAl-Al2O3 and analyzed the hardness and thermal loading performance of the coating. It was inferred that the coating possesses excellent resistance to shock and erosion for elevated impact angles and temperature. K. Padilla and E.S. Puchi Cabrera et al. [18,19], have studied fatigue behavior of AISI 4140 steel under various conditions of coating with Ni based alloy, grit blasting by alumina, as polished and coating from HVOF method. They revealed that, the reduction in fatigue strength is approximately 95% at 460 MPa whereas it reaches 74% at 580 MPa. Presence of tensile residual stresses in the material was mainly due to extensive fracture and separation of the coatings from the specimen as shown in Fig. 4. E. Celikand O. Culha et al. [20,27], investigated WC-based HVOF coatings on roller cylinder. The developed coatings were studied using optical microscopy, SEM, image analyzer and micro hardness. Scratch tester is used for measuring adhesion strength of the coatings. Compared to other coatings (WC-Co, NiAl and stainless steel) the micro hardness of WC-Ni is higher. The adhesion capacity of WC-Ni is 76.2 MPa and WC-Co is 125.9 MPa. The surface roughness of WC-Ni is more compared to WC-Co. The surface is less porous with minimal oxide content and excellent interfacial contact. Gourhari Ghosh et al. [21], diamond abrasive grains were employed which exerts high stress leading to either pulverization, cracking or plastic deformation of WC grains. In Semi Autogeneous Grinding, plastic flow behavior (plasticity) aids in material removal rather than brittle fracture. Due to combination of chemical etching and mechanical abrasion, chemical assisted autogeneous grinding is effective and efficient in attaining good finish. A. Ibrahim et al. [22,23], compared the fatigue and deformation behavior of two sets of AISI 4340 steel substrate. One set is coated by WC-CO based HVOF and another coating by hard chrome. The morphology of the substrates will be evaluated using Optical and SEM microscopy. Hard chrome deposition method results in build-
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
4
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 7. SEM images of the (A) surface morphology and (B) cross-section of NiAl powder [42].
ing up of residual stresses causing crack formation leading to reduction in fatigue strength property. The Stiffness factor for HVOF WC-17Co is more than hard chrome plating, which indicates higher efficiency and improved fatigue strength of coated substrate as shown in Fig. 5. Also observed that, to obtain effective Titania coatings with improved mechanical performance, the best substitute for conventional method of APS is HVOF coating of nano structured ceramic materials. J. R. Garcia et al. [25], observed the effects of fatigue on medium carbon steel coated with WC thin coatings deposited by HVOF technique. Fatigue resistance is assessed for coated, uncoated, laser surface hardened and WC coated treated by laser. The fatigue resistance of the coated test samples is more compared to uncoated samples. The fatigue strength of the coating decreases due to repeated exposure to high temperatures resulting in crack initiation. R. C. Souza et al. [26], studied the impact of Cr and WC based coatings using HVOF and chromium electroplating on wear, corrosion and fatigue property of AISI 4340 steel. S-N curves were plotted for base material, HVOF coated and chromium plated specimens using axial fatigue tests. Experimental results indicate that Cr and WC based HVOF coated specimens have improved micro hardness and abrasive wear resistance compared to chromium electroplated as shown in Fig. 6. 3. Tribological properties Tom Peat et al. [28], examined the effects of Aluminum Oxide, Chromium Carbide and Tungsten Carbide HVOF coatings under dry and slurry erosion environment. Highest mass and volume loss were exhibited by Cr based coatings while least volume loss was shown by WC based coatings with a reduction in wear scar depth by 64%. Tungsten Carbide in combination with a Cobalt binder established a strong protective coating leading to minimal loss of material compared to other coatings. N. Jegadeeswaran et al. [29], observed the oxidation performance of titanium-based alloy at high temperatures. An appropriate protective HVOF coating was coated on Ti-31 alloy to prevent oxidation, to progress the lifespan and efficacy of material. The results revealed the presence of incompletely melted powder particles and reduction in porosity of the structure. The formation of metal oxides has helped in gaining required oxidation resistance. Petra Gavendová et al. [30], they combined cold gas dynamic spraying and electron beam remelting to enhance bond coat characteristics. The results revealed that, HVOF coatings have excellent bonding with substrate compared to CGDS. Higher porosity has been detected in inter dendritical space of CGDS samples. N. D. Prasanna et al. [31], their investigation is based on varieties of turbine alloys coated with Co-Ni based HVOF coatings.
Mechanical properties and microstructure of these coatings has been studied. From their studies it is revealed that, HVOF techniques have been used effectively to apply coatings on turbine alloys. Stellite-6 coatings show lesser rate of erosion related to the other coating materials. Teng wang et al. [32], analyzed the wear conduct of HVOF sprayed tungsten carbide coatings at elevated temperature. Sliding tests at high temperatures were conducted on WC-Co coating to analyze wear properties. The results revealed that, with increase in temperature, the wear rate and average friction coefficient enhanced substantially. Post heat treatment, the micro hardness was improved due to reduction in porosity and increasing the coating density. Sheng Hong et al. [33], evaluated the characteristics of HVOF WC based cermet coatings and stainless steel under slurry erosion and microbial corrosion condition. The results of potentio dynamic polarization and EIS reveals that WC coating possesses a microbial based corrosion resistance in seawater environment initiated by sulphate reducing bacteria. Pengbo Mia et al. [34], examined the effects of HVOF WC coating with a low decomposition degree on mild steel substrate. The structure, wear performance and mechanical properties were investigated at elevated temperature. Coating exhibits a solid microstructure and bimodal WC particle size distribution. It possesses enhanced hardness and excellent fracture toughness. Friction coefficient decreases with increase in temperature. Sarka Houdkova et al. [35], examined laser clad coatings, laser remelted HVOF coatings and HVOF as sprayed using XRD, SEM and sliding wear test. The tests revealed that, Laser Clad coating possess better aversion to wear by sliding mode over other coating varieties Murilo S. Lamana et al. [36], performed a study on the cavitation induced erosion behavior of WC based coatings on AISI 1008 steel surface. Two cermets with varied configuration are coated using HVOF-LF and HVOF-GF techniques. The main highlights are, greater compressive stresses for both configurations were developed due to higher velocity of particles in HVOF-LF process resulting in greater coating density. HVOF-LF WC-17Co coating showed maximum cavitation erosion resistance. C. Zhang et al. [37], investigated amorphous coatings (Fe48Cr15Mo14C15B6Y2) produced by HVOF process under dry sliding environments with alumina ball as the counterpart. Wear resistance is more pronounced in Fe-based amorphous coatings compared to conventional methods. The load does not have any impact on the wear rate, but sweeps linearly with increasing sliding speed. Giovanni Bolelli et al. [38], analysed the wear characteristics of HVAF sprayed Fe-31Cr-12Ni-3.6B-0.6C(wt%) deposition as a function of coating attributes. The two variables namely gas pressure and powder feed rate were varied. The results revealed that ero-
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
sion by cavitation of HVAF based specimens contain a 60 min as incubation period during which nucleation of interlamellar fatigue cracks are initiated. J. Morales-Hernandez et al. [39], reported corrosion and erosion rate of turbine steel coated with MCrAlY and Diamalloy 4006 produced on stainless steel by HVOF process. The Sintering procedure progresses the interdiffusion process among different states in the coating contributing to the reduction in porosity resulting in enhanced interface with the specimen. Electrochemical results illustrate better corrosion resistance. Archana Shriram Hajare et al. [40], compared tungsten carbide and chromium carbide applied by HVOF technique. The mechanical and coating characterization were done using SEM, EDS, XRay diffractometer and wear testing machine. Tungsten carbide coated specimens exhibits lower porosity and surface roughness related to chromium carbide coatings. WC displays improved wear strength compared to Cr coatings. The thermal properties of two different coatings display substantial result on the wear performance of the two coatings. Mitra AkhtariZavareh et al. [41], focused mainly on carbon steel substrates which are used in oil and gas industry. Al8Si20BN ceramic powder having exceptional wear and corrosion resistance is sprayed with plasma spray and HVOF methods. HVOF sprayed specimens showed better results based on micro structural analysis, wear and corrosion testing compared to plasma coated specimens. Mingwen Bai et al. [42], performed corrosion test for biomassfired boiler. 304 stainless steel were coated with Ni-Al by HVOF process to safe guard the boiler steel against corrosion initiated in the presence of chlorine. There is an observed corrosion of specimens due to diffusion ofCl2 and O2startingfrom the edges to the middle due to fast growing Al2O3. as shown in Fig. 7. Marcelino P. Nascimento et al. [43], investigated AISI 4340 steel behavior on abrasive wear, fatigue and corrosion test coated by HVOF methods and fluoride free chromium electroplating in contrast to hard chromium electroplating. The calculated wear loss presents improvement in the results attained by HVOF tungsten carbide coating in contrast with chromium electroplating. Improved corrosion resistance was obtained for HP/HVOF tungsten carbide coating. The fatigue strength is more pronounced in samples deposited by chromium electroplating compared to tungsten carbide. R. J. K. Wood et al. [44], coated commercially pure Al and Al/12% Si eutectic alloy on AISI 1020 carbon steel specimens using HVOF technology. It has been observed that, mass losses will be greater at nominally normal incidence for HVOF and hot dipped zinc coatings compared to nominally oblique incidence. Aluminum based coatings are less liable to flow corrosion compared to galvanized steel under 3.5 m/s. C. Godoy et al. [45], tried to increase corrosion strength of WCCo coating neither by varying the constituents of the coating nor by subjecting to post-melt. Immersion tests and potentio dynamic tests were conducted in HCl and H2SO4. The duplex WC-Co/NiCrAl coating is more effective to safeguard AISI 1020 steel specimen from corrosion. Chemical analyses conducted after potentio dynamic trials predicted that post-melted coating is the best efficient system in shielding the specimen from H2SO4 medium. B. Song et al. [46], analyzed the behavior ofNi50Cr gas atomized powder which is coated on a power plant alloy by gas fueled and liquid fueled HVOF, laser cladding and Cold gas dynamic spray. The corrosion products were analyzed using SEM. In all varieties of coatings, when KCl is not present continuous oxide scale is formed and the presence of KCl deposit results in further deterioration of oxide scale.
5
Feizabadi et al. [47], coated Hastelloy substrate with two MCrAlY powders (NiCoCrAlY and CoNiCrAlY) using HVOF process and it is exposed to 1000 °C air for evaluating their cyclic oxidation behavior. The coatings were examined using X-ray diffraction, energy dispersive X-ray spectroscopy and scanning electron microscopy. It was proved that, Ni based coating is enclosed with aAlumina protective phase but the oxide phase that develops on the coating is h-Alumina. B. Uyulgan et al. [48], reported wear performance of FeCr and Ni based coatings deposited by HVOF technique on carbon steel substrate. The coated layers were studied using optical microscopy, surface roughness and micro hardness testers. Micro structural analysis revealed that coatings have spherical particles, oxides, cracks and porosities. Sukhpal Singh Chatha et al. [49], have identified the effects of 75Cr3C2-25NiCr coating by HVOF method on tempered boiler steel. The mechanical and metallurgical properties were reviewed. Cr3C2-NiCr coatings render outstanding corrosion and oxidation resistance, also exhibit peak melting point and hardness, wear resistance and strength at elevated temperature. The resistance to erosion of cermets coatings rises with surge in chromium carbide content. Mitra Akhtari Zavareh et al. [50], coated Cr3C2-NiCr on carbon steel by HVOF technology. The coatings are examined for wear and corrosion behavior. The microstructure and wear properties are analyzed using SEM analysis and Pin-on-disk tester. Cr3C2-20NiCr deposited layer has significant effect on the features of carbon steel in corrosion and wear characteristics.
4. Conclusions Based on the survey the following conclusions were drawn: Thermal spray coatings by HVOF technology reduced the tensile residual stresses on base metal and improve micro hardness compared to electroplating. The shot peening process showed effective results in controlling the fatigue life of the material by increasing the axial fatigue strength. HVOF coatings subjected to shot peening exhibits higher fatigue, corrosion and wear strength. HVOF sprayed coatings have higher erosion resisting performance and durability when compared to other methods. Salt spray test revealed that HVOF thermal spray coatings possess improved corrosion resistance compared to other techniques. HVOF coatings showed better abrasive wear strength with minimum weight loss compared to conventional hard chromium plating. So, selection of coating material, deposition technology and optimum coating thickness for AISI 4340 steel which has leading application in aircraft components is not observed in available literature which needs further research. References [1] [2] [3] [4] [5] [6] [7] [8] [9] [10]
SulzerMetco, High Velocity Oxy-Fuel (HVOF) Solutions. Industrial Surface Technologies Inc. L.F.S. Vieira, H.J.C. Voorwald, M.O.H. Cioffi, Procedia Eng. 114 (2015) 606–612. R.G. Bonoraa, H.J.C. Voorwald, M.O.H. Cioffi, G.S. Junior, L.F.V. Santos, Fatigue 2010, Procedia Eng. 2 (2010) 1617–1623. M. Manjunatha, R.S. Kulkarni, M. Krishna, AMME 2014,, Procedia Mater. Sci. 5 (2014) 622–629. D. Deesom, K. Charoenrat, S. Moonngam, C. Banjongprasert. Surface and coating technology, DOI:10.1016/j.surfcoat.2016.06.016. N. Jegadeeswaran, M.R. Ramesh, K. UdayaBhat, IConDM 2013, Procedia Eng. 64 (2013) 1013–1019. G.S. Junior, H.J.C. Voorwald, L.F.S. Vieira, M.O.H. Cioffi, R.G. Bonora, Fatigue 2010, Procedia Eng. 2 (2010) 649–656. Cheng Hung Yeh, Wu Tai Chieh, Che Hua Yang, International congress on ultrasonics, Phys. Procedia 70 (2015) (2015) 492–495. Nagaraja C. Reddy, B.S. Ajay Kumar, H.N. Reddappa, M.R. Ramesh, Praveennath G. Koppad, S. Kord, Journal of Alloys and Compounds, March 2018 (accepted Manuscript).
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
6
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
[11] L. Hernandeza, F. Oliveiraa, J.A. Berríosb, C. Villalobosb, A. Pertuza, E.S. Puchi Cabrera, Surf. Coat. Technol. 133–134 (2000) 68–77. [12] M.P. Nascimento, R.C. Souza, W.L. Pigatin, H.J.C. Voorwald, Int. J. Fatigue 23 (2001) 607–618. [13] H.J.C. Voorwald, R.C. Souza, W.L. Pigatin, M.O.H. Cioffi, Surf. Coat. Technol. 190 (2005) 155–164. [14] Liyong Ni, Chungen Zhou, Mater. Int. 22 (3) (2012) 237–243. [15] F. Oliveira, L. Hern andez, J.A. Berr, C. Villalobos, A. Pertuz, Surf. Coat. Technol. 140 (2001) 128–135. [16] Li-yong Ni, Wu Zi-long, Chun-gen Zhou, Prog. Natural Sci.: Mater. Int. 21 (2011) 173–179. [17] Buqian Wang, Seong W. Lee, Wear 239_2000. 83-90. [18] K. Padilla, A. Vela squez, J.A. Berrios, E.S. Puchi Cabrera, Surf. Coat. Technol. 150 (2002) 151–162. [19] E.S. Puchi Cabrera, J.A. Berrios, J. Da-Silva, J. Nunes, Surf. Coat. Technol. 172 (2003) 128–138. [20] E. Celika, O. Culha, B. Uyulgan, N.F. Ak Azem, I. Ozdemir, A. Turk, Surf. Coat. Technol. 200 (2006) 4320–4328. [21] Gourhari Ghosh, Ajay Sidpara, P.P. Bandyopadhyay, Surf. Coat. Technol. (2017). [22] A. Ibrahim, C.C. Berndt, Mater. Sci. Eng. A 456 (2007) 114–119. [23] A. Ibrahim, R.S. Lima, C.C. Berndt, B.R. Marple, Surf. Coat. Technol. 201 (2007) 7589–7596. [24] H.J.C. Voorwald, L.F.S. Vieira, M.O.H. Cioffi, Procedia Eng. 2 (2010) 331–340. [25] J.R. Garcia, J.E. Fernandez, J.M. Cuetos, F.G. Costales, Eng. Failure Anal. 18 (2011) 1750–1760. [26] R.C. Souza, H.J.C. Voorwald, M.O.H. Cioffi, Surf. Coat. Technol. 203 (2008) 191– 198. [27] O. Culha, E. Celik, N.F. Ak Azem, I. Birlik, M. Toparli, A. Turk, J. Mater. Process. Technol. 204 (2008) 221–230. [28] Tom Peat, Alexander Galloway, Athanasios Toumpis, David Harvey, Wei-Hua Yang, Surf. Coat. Technol. 300 (2016) 118–127. [29] N. Jegadeeswaran, M. R. Ramesh, K. UdayaBhat, International Conference on Advances in Manufacturing and Materials Engineering, AMME 2014, Procedia Materials Science 5 (2014) 11–20. ˇ ízˇeka, Jan C ˇ upera, Makoto Hasegawa, Ivo Dlouhy´, [30] Petra Gavendová, Jan C Procedia Mater. Sci. 12 (2016) 89–94.
[31] N.D. Prasanna, C. Siddaraju, Gagan Shetty, M.R. Ramesh, Madhusudhan Reddy, Mater. Today: Proc. 5 (2018) 3130–3136. [32] Teng Wang, Fuxing Ye, Int. J. Refractory Metals Hard Mater. 71 (2018) 92–100. [33] Sheng Hong, Yuping Wu, Wenwen Gao, Jianfeng Zhang, Yugui Zheng, Yuan Zheng, International Journal of Refractory Metals and Hard Materials. (accepted manuscript). [34] Pengbo Mi, Hongjian Zhao, Teng Wang, Fuxing Ye, Materials Chemistry and Physics, (accepted manuscript). [35] Sarka Houdkova, Zdenek Pala, Eva Smazalova, Marek Vostrak, ZdenekC esanek, Surface & Coatings Technology, (accepted manuscript). [36] Murilo S. Lamana, Anderson G.M. Pukasiewicz, Sanjay Sampath, Wear 398– 399 (2018) 209–219. [37] C. Zhang, L. Liu, K.C. Chan, Q. Chen, C.Y. Tang, Intermetallics 29 (2012) 80–85. [38] Giovanni Bolelli, Andrea Milanti, Luca Lusvarghi, Lorenzo Trombi, Heli Koivuluoto, Petri Vuoristo, Tribol. Int. 95 (2016) 372–390. [39] J. Morales-Hernández, A. Mandujano-Ruiz, F. Castañeda- Zaldivar, R. AntañoLópez, J. Torres- González, MicroEchem 2013, Procedia Chem. 12 (2014) 80– 91. [40] Archana Shriram Hajare, C.L. Gogt, Mater. Today: Proc. 5 (2018) 6924–6933. [41] Mitra Akhtari Zavareh , Ehsan Doustmohamadi, Ahmed Sarhan , Ramin Karimzadeh, Pooria Moozarm Nia, Ramesh Singh Al/Kulpid Singh, ceramic coatings, 2018. [42] Mingwen Bai, Liam Reddy, Tanvir Hussain, Corros. Sci. 135 (2018) 147–157. [43] Marcelino P. Nascimento, Renato C. Souza, Ivancy M. Miguel, Walter L. Pigatin, Herman J.C. Voorwald, Surf. Coat. Technol. 138 (2001) 113–124. [44] R.J.K. Wood, A.J. Speyer, Wear 256 (2004) 545–556. [45] C. Godoy, M.M. Lima, M.M.R. Castro, J.C. Avelar-Batista, Surf. Coat. Technol. 188–189 (2004) 1–6. [46] B. Song, K.T. Voisey, T. Hussain, Surf. Coat. Technol. (2018). [47] M. Salehi Feizabadi, S.K. Doolabi, M. Rezaei Sadrnezhaad, J. Alloys Compd. (2018). [48] B. Uyulgan, E. Dokumaci, E. Celik, I. Kayatekin, N.F. Ak Azem, I. Ozdemir, M. Toparli, J. Mater. Process. Technol. 190 (2007) 204–210. [49] Sukhpal Singh Chatha, Hazoor S. Sidhu, Buta S. Sidhu, J. Miner. Charac. Eng. 569–586 (2012). [50] Mitra AkhtariZavareh, Ahmed AlyDiaa Mohammed, Sarhan, Bushora Binti AbdRazaka, Wan Jeffrey Basirun, Ceram. Int. 41 (2015) 5387–5396.
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review G. Padmavathi a,⇑, B.N. Sarada b, S.P. Shanmuganathan a, B.V. Padmini c, N. Mohan d a
Dayananda Sagar College of Engineering, Bangalore, Karnataka 560078, India BMS College of Engineering, Bangalore, Karnataka 560080, India c Sambhram Institute of Technology, Bangalore, Karnataka 560004, India d Dr. Ambedkar Institute of Technology, Bangalore, Karnataka 560056, India b
a r t i c l e
i n f o
Article history: Received 1 August 2019 Accepted 17 September 2019 Available online xxxx Keywords: Corrosion HVOF coating Fatigue Wear Microhardness
a b s t r a c t Chromium has excellent wear and corrosion properties with good lubrication and chemical resistance mainly used for decorative and practical applications. Nevertheless, the necessity to recognize replacements or to enhance the mechanical characteristics of chromium electroplating is of paramount importance mainly to overcome the environmental pollution and to enhance the fatigue strength of the substrate. The main reason for chromium coatings is to improve wear and corrosion properties of the component. But the main byproduct of this process is Cr + 6 (hexavalent chromium), that is hazardous to wellbeing of the surroundings. High Velocity Oxygen Fuel thermal spray coating (HVOF) is developed as an exceptional replacement for conventional hard chromium electroplating process. HVOF coatings possess improved hardness, wear and fatigue resistance in contrast to hard chromium coatings. An attempt has been made to conduct a survey to analyze the result of mechanical and tribological characteristics of HVOF coatings. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.
1. Introduction
1.1. HVOF - thermal coating system
Thermal spraying is a process of depositing metallic and nonmetallic materials either in liquefied or semi-liquefied state on the surface of the substrate that aids in providing excellent resistance to wear, erosion and corrosion [1]. The coating by thermal spray technique involves melting of material by application of electrical arc or combustible gas followed by atomization which is initiated due to kinetic energy of the gas stream and deposited onto the substrate. After the collision of the particles, it flattens and adheres to the surface complying with the geometry of the component. Finally adhered and surface leveled particles build up to constitute the coating. High strength materials are usually coated to resist the degeneration of the surface. Coating by thermal spray technology finds relevancy in Aerospace, Automobile, Textile and Mining sectors owing to superior binding strength, lower porosity and improved hardness [2].
A chemical mixture of oxygen and fuel (kerosene) undergoes atomization as it passes through the combustion chamber. During the process a jet of stream is generated. Combinations of alloys in powder form are introduced into the stream, which is melted, atomized and forced towards the surface at very high velocity. The exertion of kinetic and thermal energy to the particles creates an effective bonding on the substrate as shown in Fig. 1. HVOF coatings possessing zero porosity, high density and hardness finds suitable applications in corrosive environments. It has very good resistance to wear, extreme heat and abrasion. HVOF coated materials are scratch proof and are bound to the base metal at strengths more than 10,000PSI by satisfying environmental/ safety standards.
⇑ Corresponding author. E-mail address: [email protected] (G. Padmavathi).
2. Mechanical properties The important mechanical properties like hardness, density, fatigue strength and corrosion resistance were studied on various coating compositions.
https://doi.org/10.1016/j.matpr.2019.09.085 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
2
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 1. Working principle of HVOF [2].
L.F.S Vieria et al. [3], The fatigue property was evaluated using shot peening method. Fractured Ni based coated AISI 4340 steel specimens were analyzed using SEM. It was inferred that spray coated specimen exhibited improved property compared to uncoated component. R.G. Bonora et al [4], compared the outcome of tungsten carbide coating done by HVOF and conventional chromium electroplating on AISI 4340 steel on fatigue behaviour. The initiation of crack growth and adherence of the coating to the substrate were observed under SEM and Optical microscopy. The results showed excellent resistance to fatigue, surface degradation and wear behaviour when compared to plating by hard chromium. Manjunatha M et al [5], used Air Jet Erosion Tester to predict the influence of Cr3C2based coatings on erosive behavior of AISI 316 Molybdenum steel. Micro Vickers Hardness and XRD analysis is used to characterize the coated samples. Their experimental results revealed that HVOF sprayed Cr3C2/NiC (85/15) % coatings showed excellent corrosion and oxidation resistance. D. Deesom et al [6], NiCr powder and different weight percentage of CNTs [0, 0.5, 1] were ball milled and CVD process is employed for developing carbon nanotubes on NiCr powder. The main observation is Vickers hardness of NiCr-CNT is 20% enhanced when compared to pure NiCr coating.
N. Jegadeeswaran et al. [7], Carried out test in salt bath environment under hot corrosion condition at 800 °C by introducing the alloy specimens Ti-31 in as-is and uncoated condition. Chromium content is more pronounced in HVOF based coating and this provides the base alloy a barrier to high temperature corrosion, shown in Fig. 2. G. S. Junior and H. J. C. Voorwald et al. [8,24], inferred that shot peening effect results in complete transformation of compressive to tensile stresses and thereby subsequent reduction in residual stresses. Scanning electron microscope is used to study crack initiation points on the fractured fatigue specimens. Fatigue limit improved by 13.3% from 750 MPa to 850 MPa. Cheng Hung Yeh et al. [9], they employed HVOF and APS methods to study the mechanical properties on Nickel-Aluminum coatings at high temperature atmosphere up to 2950c. Finally, they revealed the Young’s modulus of the specimens coated with HVOF method is higher than APS method. Nagaraja C. Reddy et al. [10], coated Ni based powder on AISI 420 stainless steel and titanium alloy by HVOF technique. Micro hardness and microstructure were examined. Both Ni3Ti and Ni3Ti+(Cr3C2 + 20NiCr) coated specimens have higher micro hardness compared to substrate materials. NiO and Cr2O3 phases developed on outer surface of coatings were found useful to hamper oxidation rate at elevated temperatures.
Fig. 3. Thermal cycling lifetime of as-sprayed, grit-blasted, shot peening, and vacuum treatment TBCs [14].
Fig. 2. SEM results of samples under hot corrosion (i)Uncoated Ti-31 (ii) Coated Ti-31 [7].
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 4. Optical micrograph of a substrate (S)–deposit (D) interface of a sample after fatigue testing [18].
Fig. 5. Stress–strain curves of coated and uncoated specimens [22].
Fig. 6. S–N curves for axial fatigue tests [26].
L. Hernandez and F. Oliveira et al. [11,15], varied the settings like uncoated, grit blasting with alumina particles, grit blasted and deposited with Colmonoy 88 using HVOF method on AISI
3
4340 steel to observe the corrosion and fatigue properties. They revealed that, resistance to the stress applied and fatigue property is improved with HVOF deposition. The corrosion life of steel coated with Colmonoy deposit is increased extensively. M. P. Nascimento et al. [12], compared the performance of WC thermal sprayed HVOF process with electroplating technique. The fatigue strength exhibited by coated specimen is more compared to electroplated specimen. AISI 4340 steel showed rising trend in fatigue strength because of shot peening process. Maximum delamination is observed at the interface between shot peened specimen and electro-less nickel under layer. H. J. C. Voorwald et al. [13], reported the influence of WC based coatings on the fatigue resistance of AISI 4340 steel deposited by HVOF process in contrast to chromium electroplating, with and without shot peening process. It was observed that, Tungsten carbide coated specimens exhibits improved fatigue strength when related to chromium electroplating. Experimental results revealed WC-10Co-4Cr HVOF coated samples have improved axial fatigue and corrosion resistance when compared with WC-17Co samples in salt fog exposure. Liyong Ni et al. [14], examined the outcomes of surface modification on thermal cycling lifetime using different process like grit blasting, vacuum treatment and shot peening methods. They revealed that, the enhancement of thermal life of coating post surface modification is due to the formation of uniform and continuous development of Aluminum oxide as shown in Fig. 3. Li-Yong Ni et al. [16], analyzed HVOF coating on Ni based alloy (NiCrAlY) for Isothermal oxidation characteristics carried out at 1050 °C. The primary formation is Aluminum Oxide but combination of Al2O3 and NiCr2O4 are developed on coatings subjected to grit-blasting and shot peening methods. Buqian Wang et al. [17], characterized the erosion-corrosion property of HVOF coated NiAl-Al2O3 and analyzed the hardness and thermal loading performance of the coating. It was inferred that the coating possesses excellent resistance to shock and erosion for elevated impact angles and temperature. K. Padilla and E.S. Puchi Cabrera et al. [18,19], have studied fatigue behavior of AISI 4140 steel under various conditions of coating with Ni based alloy, grit blasting by alumina, as polished and coating from HVOF method. They revealed that, the reduction in fatigue strength is approximately 95% at 460 MPa whereas it reaches 74% at 580 MPa. Presence of tensile residual stresses in the material was mainly due to extensive fracture and separation of the coatings from the specimen as shown in Fig. 4. E. Celikand O. Culha et al. [20,27], investigated WC-based HVOF coatings on roller cylinder. The developed coatings were studied using optical microscopy, SEM, image analyzer and micro hardness. Scratch tester is used for measuring adhesion strength of the coatings. Compared to other coatings (WC-Co, NiAl and stainless steel) the micro hardness of WC-Ni is higher. The adhesion capacity of WC-Ni is 76.2 MPa and WC-Co is 125.9 MPa. The surface roughness of WC-Ni is more compared to WC-Co. The surface is less porous with minimal oxide content and excellent interfacial contact. Gourhari Ghosh et al. [21], diamond abrasive grains were employed which exerts high stress leading to either pulverization, cracking or plastic deformation of WC grains. In Semi Autogeneous Grinding, plastic flow behavior (plasticity) aids in material removal rather than brittle fracture. Due to combination of chemical etching and mechanical abrasion, chemical assisted autogeneous grinding is effective and efficient in attaining good finish. A. Ibrahim et al. [22,23], compared the fatigue and deformation behavior of two sets of AISI 4340 steel substrate. One set is coated by WC-CO based HVOF and another coating by hard chrome. The morphology of the substrates will be evaluated using Optical and SEM microscopy. Hard chrome deposition method results in build-
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
4
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 7. SEM images of the (A) surface morphology and (B) cross-section of NiAl powder [42].
ing up of residual stresses causing crack formation leading to reduction in fatigue strength property. The Stiffness factor for HVOF WC-17Co is more than hard chrome plating, which indicates higher efficiency and improved fatigue strength of coated substrate as shown in Fig. 5. Also observed that, to obtain effective Titania coatings with improved mechanical performance, the best substitute for conventional method of APS is HVOF coating of nano structured ceramic materials. J. R. Garcia et al. [25], observed the effects of fatigue on medium carbon steel coated with WC thin coatings deposited by HVOF technique. Fatigue resistance is assessed for coated, uncoated, laser surface hardened and WC coated treated by laser. The fatigue resistance of the coated test samples is more compared to uncoated samples. The fatigue strength of the coating decreases due to repeated exposure to high temperatures resulting in crack initiation. R. C. Souza et al. [26], studied the impact of Cr and WC based coatings using HVOF and chromium electroplating on wear, corrosion and fatigue property of AISI 4340 steel. S-N curves were plotted for base material, HVOF coated and chromium plated specimens using axial fatigue tests. Experimental results indicate that Cr and WC based HVOF coated specimens have improved micro hardness and abrasive wear resistance compared to chromium electroplated as shown in Fig. 6. 3. Tribological properties Tom Peat et al. [28], examined the effects of Aluminum Oxide, Chromium Carbide and Tungsten Carbide HVOF coatings under dry and slurry erosion environment. Highest mass and volume loss were exhibited by Cr based coatings while least volume loss was shown by WC based coatings with a reduction in wear scar depth by 64%. Tungsten Carbide in combination with a Cobalt binder established a strong protective coating leading to minimal loss of material compared to other coatings. N. Jegadeeswaran et al. [29], observed the oxidation performance of titanium-based alloy at high temperatures. An appropriate protective HVOF coating was coated on Ti-31 alloy to prevent oxidation, to progress the lifespan and efficacy of material. The results revealed the presence of incompletely melted powder particles and reduction in porosity of the structure. The formation of metal oxides has helped in gaining required oxidation resistance. Petra Gavendová et al. [30], they combined cold gas dynamic spraying and electron beam remelting to enhance bond coat characteristics. The results revealed that, HVOF coatings have excellent bonding with substrate compared to CGDS. Higher porosity has been detected in inter dendritical space of CGDS samples. N. D. Prasanna et al. [31], their investigation is based on varieties of turbine alloys coated with Co-Ni based HVOF coatings.
Mechanical properties and microstructure of these coatings has been studied. From their studies it is revealed that, HVOF techniques have been used effectively to apply coatings on turbine alloys. Stellite-6 coatings show lesser rate of erosion related to the other coating materials. Teng wang et al. [32], analyzed the wear conduct of HVOF sprayed tungsten carbide coatings at elevated temperature. Sliding tests at high temperatures were conducted on WC-Co coating to analyze wear properties. The results revealed that, with increase in temperature, the wear rate and average friction coefficient enhanced substantially. Post heat treatment, the micro hardness was improved due to reduction in porosity and increasing the coating density. Sheng Hong et al. [33], evaluated the characteristics of HVOF WC based cermet coatings and stainless steel under slurry erosion and microbial corrosion condition. The results of potentio dynamic polarization and EIS reveals that WC coating possesses a microbial based corrosion resistance in seawater environment initiated by sulphate reducing bacteria. Pengbo Mia et al. [34], examined the effects of HVOF WC coating with a low decomposition degree on mild steel substrate. The structure, wear performance and mechanical properties were investigated at elevated temperature. Coating exhibits a solid microstructure and bimodal WC particle size distribution. It possesses enhanced hardness and excellent fracture toughness. Friction coefficient decreases with increase in temperature. Sarka Houdkova et al. [35], examined laser clad coatings, laser remelted HVOF coatings and HVOF as sprayed using XRD, SEM and sliding wear test. The tests revealed that, Laser Clad coating possess better aversion to wear by sliding mode over other coating varieties Murilo S. Lamana et al. [36], performed a study on the cavitation induced erosion behavior of WC based coatings on AISI 1008 steel surface. Two cermets with varied configuration are coated using HVOF-LF and HVOF-GF techniques. The main highlights are, greater compressive stresses for both configurations were developed due to higher velocity of particles in HVOF-LF process resulting in greater coating density. HVOF-LF WC-17Co coating showed maximum cavitation erosion resistance. C. Zhang et al. [37], investigated amorphous coatings (Fe48Cr15Mo14C15B6Y2) produced by HVOF process under dry sliding environments with alumina ball as the counterpart. Wear resistance is more pronounced in Fe-based amorphous coatings compared to conventional methods. The load does not have any impact on the wear rate, but sweeps linearly with increasing sliding speed. Giovanni Bolelli et al. [38], analysed the wear characteristics of HVAF sprayed Fe-31Cr-12Ni-3.6B-0.6C(wt%) deposition as a function of coating attributes. The two variables namely gas pressure and powder feed rate were varied. The results revealed that ero-
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
sion by cavitation of HVAF based specimens contain a 60 min as incubation period during which nucleation of interlamellar fatigue cracks are initiated. J. Morales-Hernandez et al. [39], reported corrosion and erosion rate of turbine steel coated with MCrAlY and Diamalloy 4006 produced on stainless steel by HVOF process. The Sintering procedure progresses the interdiffusion process among different states in the coating contributing to the reduction in porosity resulting in enhanced interface with the specimen. Electrochemical results illustrate better corrosion resistance. Archana Shriram Hajare et al. [40], compared tungsten carbide and chromium carbide applied by HVOF technique. The mechanical and coating characterization were done using SEM, EDS, XRay diffractometer and wear testing machine. Tungsten carbide coated specimens exhibits lower porosity and surface roughness related to chromium carbide coatings. WC displays improved wear strength compared to Cr coatings. The thermal properties of two different coatings display substantial result on the wear performance of the two coatings. Mitra AkhtariZavareh et al. [41], focused mainly on carbon steel substrates which are used in oil and gas industry. Al8Si20BN ceramic powder having exceptional wear and corrosion resistance is sprayed with plasma spray and HVOF methods. HVOF sprayed specimens showed better results based on micro structural analysis, wear and corrosion testing compared to plasma coated specimens. Mingwen Bai et al. [42], performed corrosion test for biomassfired boiler. 304 stainless steel were coated with Ni-Al by HVOF process to safe guard the boiler steel against corrosion initiated in the presence of chlorine. There is an observed corrosion of specimens due to diffusion ofCl2 and O2startingfrom the edges to the middle due to fast growing Al2O3. as shown in Fig. 7. Marcelino P. Nascimento et al. [43], investigated AISI 4340 steel behavior on abrasive wear, fatigue and corrosion test coated by HVOF methods and fluoride free chromium electroplating in contrast to hard chromium electroplating. The calculated wear loss presents improvement in the results attained by HVOF tungsten carbide coating in contrast with chromium electroplating. Improved corrosion resistance was obtained for HP/HVOF tungsten carbide coating. The fatigue strength is more pronounced in samples deposited by chromium electroplating compared to tungsten carbide. R. J. K. Wood et al. [44], coated commercially pure Al and Al/12% Si eutectic alloy on AISI 1020 carbon steel specimens using HVOF technology. It has been observed that, mass losses will be greater at nominally normal incidence for HVOF and hot dipped zinc coatings compared to nominally oblique incidence. Aluminum based coatings are less liable to flow corrosion compared to galvanized steel under 3.5 m/s. C. Godoy et al. [45], tried to increase corrosion strength of WCCo coating neither by varying the constituents of the coating nor by subjecting to post-melt. Immersion tests and potentio dynamic tests were conducted in HCl and H2SO4. The duplex WC-Co/NiCrAl coating is more effective to safeguard AISI 1020 steel specimen from corrosion. Chemical analyses conducted after potentio dynamic trials predicted that post-melted coating is the best efficient system in shielding the specimen from H2SO4 medium. B. Song et al. [46], analyzed the behavior ofNi50Cr gas atomized powder which is coated on a power plant alloy by gas fueled and liquid fueled HVOF, laser cladding and Cold gas dynamic spray. The corrosion products were analyzed using SEM. In all varieties of coatings, when KCl is not present continuous oxide scale is formed and the presence of KCl deposit results in further deterioration of oxide scale.
5
Feizabadi et al. [47], coated Hastelloy substrate with two MCrAlY powders (NiCoCrAlY and CoNiCrAlY) using HVOF process and it is exposed to 1000 °C air for evaluating their cyclic oxidation behavior. The coatings were examined using X-ray diffraction, energy dispersive X-ray spectroscopy and scanning electron microscopy. It was proved that, Ni based coating is enclosed with aAlumina protective phase but the oxide phase that develops on the coating is h-Alumina. B. Uyulgan et al. [48], reported wear performance of FeCr and Ni based coatings deposited by HVOF technique on carbon steel substrate. The coated layers were studied using optical microscopy, surface roughness and micro hardness testers. Micro structural analysis revealed that coatings have spherical particles, oxides, cracks and porosities. Sukhpal Singh Chatha et al. [49], have identified the effects of 75Cr3C2-25NiCr coating by HVOF method on tempered boiler steel. The mechanical and metallurgical properties were reviewed. Cr3C2-NiCr coatings render outstanding corrosion and oxidation resistance, also exhibit peak melting point and hardness, wear resistance and strength at elevated temperature. The resistance to erosion of cermets coatings rises with surge in chromium carbide content. Mitra Akhtari Zavareh et al. [50], coated Cr3C2-NiCr on carbon steel by HVOF technology. The coatings are examined for wear and corrosion behavior. The microstructure and wear properties are analyzed using SEM analysis and Pin-on-disk tester. Cr3C2-20NiCr deposited layer has significant effect on the features of carbon steel in corrosion and wear characteristics.
4. Conclusions Based on the survey the following conclusions were drawn: Thermal spray coatings by HVOF technology reduced the tensile residual stresses on base metal and improve micro hardness compared to electroplating. The shot peening process showed effective results in controlling the fatigue life of the material by increasing the axial fatigue strength. HVOF coatings subjected to shot peening exhibits higher fatigue, corrosion and wear strength. HVOF sprayed coatings have higher erosion resisting performance and durability when compared to other methods. Salt spray test revealed that HVOF thermal spray coatings possess improved corrosion resistance compared to other techniques. HVOF coatings showed better abrasive wear strength with minimum weight loss compared to conventional hard chromium plating. So, selection of coating material, deposition technology and optimum coating thickness for AISI 4340 steel which has leading application in aircraft components is not observed in available literature which needs further research. References [1] [2] [3] [4] [5] [6] [7] [8] [9] [10]
SulzerMetco, High Velocity Oxy-Fuel (HVOF) Solutions. Industrial Surface Technologies Inc. L.F.S. Vieira, H.J.C. Voorwald, M.O.H. Cioffi, Procedia Eng. 114 (2015) 606–612. R.G. Bonoraa, H.J.C. Voorwald, M.O.H. Cioffi, G.S. Junior, L.F.V. Santos, Fatigue 2010, Procedia Eng. 2 (2010) 1617–1623. M. Manjunatha, R.S. Kulkarni, M. Krishna, AMME 2014,, Procedia Mater. Sci. 5 (2014) 622–629. D. Deesom, K. Charoenrat, S. Moonngam, C. Banjongprasert. Surface and coating technology, DOI:10.1016/j.surfcoat.2016.06.016. N. Jegadeeswaran, M.R. Ramesh, K. UdayaBhat, IConDM 2013, Procedia Eng. 64 (2013) 1013–1019. G.S. Junior, H.J.C. Voorwald, L.F.S. Vieira, M.O.H. Cioffi, R.G. Bonora, Fatigue 2010, Procedia Eng. 2 (2010) 649–656. Cheng Hung Yeh, Wu Tai Chieh, Che Hua Yang, International congress on ultrasonics, Phys. Procedia 70 (2015) (2015) 492–495. Nagaraja C. Reddy, B.S. Ajay Kumar, H.N. Reddappa, M.R. Ramesh, Praveennath G. Koppad, S. Kord, Journal of Alloys and Compounds, March 2018 (accepted Manuscript).
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085
6
G. Padmavathi et al. / Materials Today: Proceedings xxx (xxxx) xxx
[11] L. Hernandeza, F. Oliveiraa, J.A. Berríosb, C. Villalobosb, A. Pertuza, E.S. Puchi Cabrera, Surf. Coat. Technol. 133–134 (2000) 68–77. [12] M.P. Nascimento, R.C. Souza, W.L. Pigatin, H.J.C. Voorwald, Int. J. Fatigue 23 (2001) 607–618. [13] H.J.C. Voorwald, R.C. Souza, W.L. Pigatin, M.O.H. Cioffi, Surf. Coat. Technol. 190 (2005) 155–164. [14] Liyong Ni, Chungen Zhou, Mater. Int. 22 (3) (2012) 237–243. [15] F. Oliveira, L. Hern andez, J.A. Berr, C. Villalobos, A. Pertuz, Surf. Coat. Technol. 140 (2001) 128–135. [16] Li-yong Ni, Wu Zi-long, Chun-gen Zhou, Prog. Natural Sci.: Mater. Int. 21 (2011) 173–179. [17] Buqian Wang, Seong W. Lee, Wear 239_2000. 83-90. [18] K. Padilla, A. Vela squez, J.A. Berrios, E.S. Puchi Cabrera, Surf. Coat. Technol. 150 (2002) 151–162. [19] E.S. Puchi Cabrera, J.A. Berrios, J. Da-Silva, J. Nunes, Surf. Coat. Technol. 172 (2003) 128–138. [20] E. Celika, O. Culha, B. Uyulgan, N.F. Ak Azem, I. Ozdemir, A. Turk, Surf. Coat. Technol. 200 (2006) 4320–4328. [21] Gourhari Ghosh, Ajay Sidpara, P.P. Bandyopadhyay, Surf. Coat. Technol. (2017). [22] A. Ibrahim, C.C. Berndt, Mater. Sci. Eng. A 456 (2007) 114–119. [23] A. Ibrahim, R.S. Lima, C.C. Berndt, B.R. Marple, Surf. Coat. Technol. 201 (2007) 7589–7596. [24] H.J.C. Voorwald, L.F.S. Vieira, M.O.H. Cioffi, Procedia Eng. 2 (2010) 331–340. [25] J.R. Garcia, J.E. Fernandez, J.M. Cuetos, F.G. Costales, Eng. Failure Anal. 18 (2011) 1750–1760. [26] R.C. Souza, H.J.C. Voorwald, M.O.H. Cioffi, Surf. Coat. Technol. 203 (2008) 191– 198. [27] O. Culha, E. Celik, N.F. Ak Azem, I. Birlik, M. Toparli, A. Turk, J. Mater. Process. Technol. 204 (2008) 221–230. [28] Tom Peat, Alexander Galloway, Athanasios Toumpis, David Harvey, Wei-Hua Yang, Surf. Coat. Technol. 300 (2016) 118–127. [29] N. Jegadeeswaran, M. R. Ramesh, K. UdayaBhat, International Conference on Advances in Manufacturing and Materials Engineering, AMME 2014, Procedia Materials Science 5 (2014) 11–20. ˇ ízˇeka, Jan C ˇ upera, Makoto Hasegawa, Ivo Dlouhy´, [30] Petra Gavendová, Jan C Procedia Mater. Sci. 12 (2016) 89–94.
[31] N.D. Prasanna, C. Siddaraju, Gagan Shetty, M.R. Ramesh, Madhusudhan Reddy, Mater. Today: Proc. 5 (2018) 3130–3136. [32] Teng Wang, Fuxing Ye, Int. J. Refractory Metals Hard Mater. 71 (2018) 92–100. [33] Sheng Hong, Yuping Wu, Wenwen Gao, Jianfeng Zhang, Yugui Zheng, Yuan Zheng, International Journal of Refractory Metals and Hard Materials. (accepted manuscript). [34] Pengbo Mi, Hongjian Zhao, Teng Wang, Fuxing Ye, Materials Chemistry and Physics, (accepted manuscript). [35] Sarka Houdkova, Zdenek Pala, Eva Smazalova, Marek Vostrak, ZdenekC esanek, Surface & Coatings Technology, (accepted manuscript). [36] Murilo S. Lamana, Anderson G.M. Pukasiewicz, Sanjay Sampath, Wear 398– 399 (2018) 209–219. [37] C. Zhang, L. Liu, K.C. Chan, Q. Chen, C.Y. Tang, Intermetallics 29 (2012) 80–85. [38] Giovanni Bolelli, Andrea Milanti, Luca Lusvarghi, Lorenzo Trombi, Heli Koivuluoto, Petri Vuoristo, Tribol. Int. 95 (2016) 372–390. [39] J. Morales-Hernández, A. Mandujano-Ruiz, F. Castañeda- Zaldivar, R. AntañoLópez, J. Torres- González, MicroEchem 2013, Procedia Chem. 12 (2014) 80– 91. [40] Archana Shriram Hajare, C.L. Gogt, Mater. Today: Proc. 5 (2018) 6924–6933. [41] Mitra Akhtari Zavareh , Ehsan Doustmohamadi, Ahmed Sarhan , Ramin Karimzadeh, Pooria Moozarm Nia, Ramesh Singh Al/Kulpid Singh, ceramic coatings, 2018. [42] Mingwen Bai, Liam Reddy, Tanvir Hussain, Corros. Sci. 135 (2018) 147–157. [43] Marcelino P. Nascimento, Renato C. Souza, Ivancy M. Miguel, Walter L. Pigatin, Herman J.C. Voorwald, Surf. Coat. Technol. 138 (2001) 113–124. [44] R.J.K. Wood, A.J. Speyer, Wear 256 (2004) 545–556. [45] C. Godoy, M.M. Lima, M.M.R. Castro, J.C. Avelar-Batista, Surf. Coat. Technol. 188–189 (2004) 1–6. [46] B. Song, K.T. Voisey, T. Hussain, Surf. Coat. Technol. (2018). [47] M. Salehi Feizabadi, S.K. Doolabi, M. Rezaei Sadrnezhaad, J. Alloys Compd. (2018). [48] B. Uyulgan, E. Dokumaci, E. Celik, I. Kayatekin, N.F. Ak Azem, I. Ozdemir, M. Toparli, J. Mater. Process. Technol. 190 (2007) 204–210. [49] Sukhpal Singh Chatha, Hazoor S. Sidhu, Buta S. Sidhu, J. Miner. Charac. Eng. 569–586 (2012). [50] Mitra AkhtariZavareh, Ahmed AlyDiaa Mohammed, Sarhan, Bushora Binti AbdRazaka, Wan Jeffrey Basirun, Ceram. Int. 41 (2015) 5387–5396.
Please cite this article as: G. Padmavathi, B. N. Sarada, S. P. Shanmuganathan et al., Effects of high velocity oxy fuel thermal spray coating on mechanical and tribological properties of materials–A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.085