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Experimental Study of Wear Behaviour on Al-2014 Alloy Coated with Thermal Spray HVOF (High Velocity Oxy-Fuel) and Plasma Spray Process– A Review
Available online at www.sciencedirect.com
ScienceDirect Materials Today: Proceedings 18 (2019) 5151–5157
www.materialstoday.com/proceedings
ICMPC-2019
Experimental Study of Wear Behaviour on Al-2014 Alloy Coated with Thermal Spray HVOF (High Velocity Oxy-Fuel) and Plasma Spray Process– A Review Ram Subbiaha, A.Arunb*, A.Anitha Lakshmic, A Naga Sai Harikad, N.Rame, N.Sateeshf a
Associate Professor, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad,,India b* M.Tech,, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad India c, Assistant Professor, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad, India d,e B.Tech, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad,,India F Professor, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad,,India
Abstract In this present review, wear are basic issues found in the piston. Thermal spray coatings are one of many techniques for adjustment of part's surface properties. The technology depends on the principle of melting and speeding of fine particles and their rapid solidification after effect on the substrate. Amongst all the techniques of thermal spray coatings, HighVelocity Oxy-Fuel and Plasma spray process is widely used in various applications. In this study, Al8Si20BN ceramic powder with explicit properties was selected, which was sprayed with high-speed oxygen fuels (HVOF) and plasma spray methods on aluminum alloys 2014. Both the coatings have same binder with equivalent rate. The coatings were characterizations were carried out with the help of Scanning Electron Microscope, X-ray Diffractometer, and Pin-on-disc wear testing machine. Its wear behavior was verified by the application of 5, 10, 15 and 20N loads of pins of the machine per disc, then the results of both methods were compared. According to the results, the models with HVOF coating are more durable than the models coated with plasma at different loads in a similar state. © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019 Keywords:optimization:Thermal Spray Coatings, HVOF Coating, Plasma coating, Wear resistance, Pin-On-Disc,aluminum alloys.
* Corresponding author. Tel.: +91 8801388883 E-mailaddress: [email protected]
2214-7853© 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
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1. Introduction The coating is a thin film of a material bonded to metal to include surface-specific properties, such as Resistance to oxidation or corrosion, attractive appearance, resistance to wear, color, electrical resistance or thermalProtection. The coating components were in the form thermal spraying contain alloys, ceramics, metals, composites and plastics. These coating components are used in a powder / a wire form, heated to a molten/semi molten state and from this point they are pulverized into micrometer-sized particles and accelerated to the substrate. The collection of innumerable spray particles results in the form of new coatings as described by B. Lei et al [2]. Contrary to other coating techniques, such as physical, chemical and galvanic vapor deposition, thermal spraying has a huge area with high details of the deposition ratio of M. Akhtari Zavareh et al [7]. Many forms of thermal spray coating are currently available to increase various surface properties of the metal part. HVOF thermal spraying and plasma spraying are widely used to produce wear-resistant coatings and the coating is an electrochemical process that changes the metal surface in a decorative, durable way, which increases corrosion and wear. This is the procedure in which finely isolated metallic or non-metallic materials are kept in the liquid or semi-liquid state to shape a point by point covering by M. Akhtari Zavareh et al [7]. The covering material can be a powder, a clay pole, a wire or a liquid material. This is profitable in view of its capacity to deliver a fired based covering that has a lower porosity than other generally utilized thermo test splashing forms, traditional circular segment showering or plasma showering. The aluminum silicon matrix (AlSi) is a chemically composite material that can be utiised in numerous abrasive coating systems to its great combination of wear and versatility. The silicone present in the material is practically pure, acts to increase the hardness of the coatings made of rigid materials and increases the resistance to abrasion. These properties cause immense application in several industries, as demonstrated by F. Toptan, et al. Silicon alumina is an important low-melting temperature eutectic system of B. Lei et al [2]. The conditions of dry sliding are utilized to explore the wear properties of these ceramics. 2. Materials and Processes 2.1. About Workpiece & coating powder materials The substrate was prepared of Aluminium 2014 grade alloy with the following proportions: Cu 4.62%, Fe 0.252%, Cr 0.008%, Mn0.849%, Si 0.764%, Mg 0.544%, Zn 0.094%, Ti0.041% and the remaining balance of Al (%) . The Aluminium specimens were prepared in 8 diameters x 50 mm pieces. The examples are firstly cleaned with ultrasonically in alcohol and then with acetone. Al8Si20BN powder with a 22-26μm nominal particle size was deposited. 2.2. Coating methods The most versatile coating strategy among all thermal spray systems is the plasma coating in L. Lacroix, et al [10]. A circular segment is formed between two electrodes in a plasma gas that regularly comprise of argon / helium or argon / hydrogen as a characteristic of the plasma spray apparatus. The extension and acceleration between the moulded nozzle and the creation of Mach (Ma) 2 speeds are controlled by heating the gas plasma electrode. The temperature of the plasma flow is still 17,000 ° F (9,500 ° K) within a few centimetres of the nozzle outlet, the temperature in the arc area continues to the detail of 36,000 ° F (20,000 ° K) by A. Sarhan et al [11]. Through the use of distinctive nozzle type, the elasticity of injection systems associated with the ability to create highly prepared temperatures involving the use of different coatings in plasma spray. The coatings flow from lowmelting polymers, such as nylon, to extremely high melting points, such as refractory materials including tantalum, ceramic oxides, tungsten and other refractory components. By using thermal protection, the materials will last longer and will work better at higher temperatures, which will result in a better overall system performance by N. Eliaz et al [15].
R. Subbiah et al. / Materials Today: Proceedings 18 (2019) 5151–5157
(a)
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Plasma spray process
(b) HVOF spray process Fig. 1: Represents the coating process of (a) Plasma spray, (b) HVOF spray.
In the plasma spray coating was performed with a plasma gun manufactured by Sulzer Metco. As shown in Fig. 1 (a) the plasma parameters used for powder spraying of Al8Si20BN are: current of 250 amps, voltage of 63 V and argon flow rate of 123.5 and 32 L / min (Ar) as gas essential and hydrogen (H2) as an optional gas separately. The spray rate is 31 g / min (4.1 lb./hour) Ag gas at a flow rate of 10.8 L / min serves as a support for infusing the plasma jet coating material. HVOF is widely used for the production of wear-resistant coatings, such as ceramic and metal mixtures, such as tungsten carbide and cobalt. In addition, HVOF can produce extremely thick coatings (with a porosity of less than 0.5%). For example, they can be used for high-tech medical instruments that are used in complex medical procedures or in simple materials in the chapter. Blancet al [9]. In this study, a HVOF thermal spray coating was performed using a Sulzer-MetcoDJ 2700 hybrid as shown in Fig. The propylene flow rate is 189 L / min, and the O2 flow rate is 345 L / min. To predict, for example, the overheating within the coating, compact air is used at a flow rate of 698 L / min to cool the sample holder until the speed of the spray gun's navigation remains stable. The particles are injected axially and centrally, the spray separation is set at 220 mm and the spray rate is 33 g / min. 2.3. Wear Tests Different types of physical tests were carried out in this segment, including porosity, density, roughness, micro hardness and joint strength, accompanied by a wear test in different loads. The hardness of the coating is calculated by coating the transverse faces using a HMV-Shimadzu device at 250g load for 13 seconds. The roughness of the coating surface (Ra) was estimated at a sum of 100 Ra points using an Alicona 3D infinity analyzer. The coated surface is institutionalized with ASTM 633 and depends on a flat circle of 1 "+ 0 / -0.005" [17]. ASTM C633 is used to calculate the strength of the coating / substrate bond. 3.
Result Analysis and Discussion
The wear test was completed with the TR-20LE with a pin-on-disk. Wear tests on uncoated and coated samples were completed using four loads. The examples were cleaned with SiC sheets at a disk speed of 180 rpm in the dry state. The speed of sliding (v = 1 m / s) and the diameter of the track (D = 40 mm) are consistent in all studies. The wear test is completed within one hour until the wear ratio of the coated examples changes and the wear rate is balanced for each individual example at a displacement distance of approximately 9108.96 m. To improve the reliability of the result, each test is processed with a similar load and a condition of five samples. After a wear test, the examples are cleaned with ultrasound with ethanol and then dried.
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(a) Plasma (b) HVOF Fig.2: AlSiBN coated samples for (a) Plasma (b) HVOF coating methods
3.1 Morphological characterization As shown in Fig. 2, the coated samples show that the coated layer provides the substrate in succession and follows well. Here the plasma coating contains numerous pores of different sizes and this porosity specifically affects wear. The sample coated with HVOF has a very dense surface. Figure 3. the surfaces of the transmission electron microscope (FESEM) in the field of samples coated with plasma and HVOF techniques in various extensions. However, during spraying, the temperature of the powder is not adequate, so that a somewhat molten area is formed in the upper part of the Al matrix as M. Yan et al [24]. Figure 3 shows several porous sections in both types of coatings. A platelet form BN dispersed in the Al matrix and pores almost interconnected in the Al-BN layer. A complete region is represented by the matrix of Al, where Si and BN are dispersed.
(a) Plasma spray process
(b) High Velocity Oxy Fuel Process
Fig. 3. at different magnifications of FESEM of Al8Si20BN coated samples: (a) 300 x, 2000 x (b) 300x, 2000 x
The silicon particles removed leave the pores as blunt points in the morphology as described by Bobzin et al. (2012) [13]. HVOF coatings are denser than plasma coatings. Johnston et al. [12]. This is due to the impact of rapid particle coatings, resulting in a high quality durable individual signs and a high thickness by A. A. Niakan et al. [25] As a result of the charge created during rapid hardening, cracks and pores are formed vertically in the plates. In general, homogeneous coatings without insulation are essential to increase erosion and block wear of the coating by J. Wu et al [28]. In fig. 3. (a, b), porosity and pore size in plasma samples are significantly greater than in samples coated with HVOF. 4. Wear Behaviour The two coated samples with plasma and HVOF were achieved a normal micro hardness of 160 and 210 HV separately. The hardness in the SiBN area is higher and lower in the aluminum area. And the density of the coating straightly affects the hardness of the coating, so the hardness of the HVOF test is greater than that of the plasma layer. As indicated by Bobzin et al. [13], the normal micro hardness of this chemical composition covered by the plasma technique is approximately 156 HV. Rolink et al. It has also been shown that the micro hardness of Al20 Si is approximately 147 HV of J. Wu et al [28].
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Regarding the application, it is important that M. Qian et al [26] apply the strength of the bond between the coated layer and the useful life of the coating. The examples in this research work were coated to accomplish a high elasticity (binding). The study of the binding strength of the samples showed that the plasma binding strength of 1600-2100 Psi was lower than the HVOF with 1900-2800 Psi. by the results of Wu et al. (2006) [20]. The roughness values of the samples coated with plasma and HVOF are 3.8 and 4.6 μm individually. As the roughness results show, the samples with HVOF coating are thicker than the plasma. The wear resistance of a smooth surface decreases from HY. Al-Fadhli et al [17]. Figure 4. shows FESEM images of carbon steel samples with extreme loads (20 N). Figure 4. (a) shows a noticeable crack that ends with deformation after being loaded at the end of the substrate surface. In fig. 4. (b) It is obvious that carbon steel shows that it is worn. At the end of the wear test, profound and wide notches are shaped superficially, and traces of wear are obvious on the whole surface.
(a) FESEM-800x
(b) FESEM-500x Figure. 4. FESEM images for carbon steel samples at load (20 N)
(c) FESEM-7000x
These traces of wear are with the pin on disc device during wear test. According to fig. 4. (c), the larger increase neatly shows the worn surface of the steel sample and wear residue. This study means that due to the surprisingly high loading on the sample, the surface of the steel has lost a detectable measure of the parts. The surface is rough as a result of wear of the residue. Figure 5 shows FESEMs of residual wear in Al8Si20BN plasma and samples coated with HVOF at load (20 N). As shown in FIG. 5 (a, b), the pins of the sample coated with plasma are lighter than the HVOF in Fig. 5 (c, d). In addition, the rate of removal of material from the sample surface of the plasma layer is significantly higher than that of the sample with HVOF.This conception indicates that this pile is excessively high for the sample coated with plasma. The proximity of the cavities in the plasma coating further aggravated the accident of the coating of J. Wu, J. Yang, et al. [28]
(a) FESEM-500X
(b) FESEM-1000X
(c) FESEM-500X
(d) FESEM-1000X
Figure.5 FESEM for the ear of sample residues coated with Al8Si20BN at load (20 N) for (a), (b) Plasma coating, and (c), (d) HVOF coating
Therefore, the plasma coating has a lower resistance to wear due to the Maximum load is applied, the surface of the sample is more worn than the HVOF sample and the trace of the pins is obvious. This is mainly due to the abundant surface porosity of M. Yan et al [24]
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In addition, Lei et al. (2014) [16] specify that a delicate matrix rich in aluminum disappears quickly, but solid SiBN particles slow down the wear process. This is related to the increase in the strength of the link between the characters and the component, as well as to the important role that the binding force of propagation and protection of the sign can have since the beginning of a break of Y.Cao et al [18]. The FESEM of the plasma-coated coatings of Fig. 5 (a, b), the deposits formed by partially molten droplets and the coated samples have a specific amount of porosity. In fig. 5 (c, d), there was an insignificant probability of SiBN in the aluminum matrix of the HVOF spray coating since this matrix contained the SiBN particles in a categorical manner and the deposited layer was extremely thick by J. Wu et al.[28]. The standards for normal wear and weight reduction for carbon steel and plasma-coated samples and HVOF, respectively, below 5, 10, 15 and 20 N load. The average use by the plasma method which varies from 195 to 650 mg for different loads, while for HVOF the normal wear varies from 67 to 108 mg. 5. Conclusion From the above study as per the micro structural investigation with wear testing, the HVOF-sprayed samples performed better plasma-sprayed samples. The wear properties of HVOF-coated examples at different loads show greater durability and the rate of weight reduction of these examples is limited, especially at loads of 5 and 10 N. Thus, for the structure of the substance, the HVOF method refines the plasma technique in terms of wear resistance. References [1] AA. Younis, W. Ensinger, MMB. El-Sabbah and R. Holze, Corrosion protection of pure aluminium and aluminium alloy (AA7075) in salt solution with silane‐ based sol–gel coatings, Materials and Corrosion 64 (2013) 276-283. [2] B. Lei, M. Li, Man, Zh. Zhao, L. Wang, Y. Li, and F. Wang, Corrosion mechanism of an Al–BN abradable seal coating system in chloride solution, Corrosion Science 79 (2014) 198-205. [3] S. Ghosh, D. Choudhury, N. Das, N. Shekhar,B.Pingguan-Murphy, Tribological role of synovial fluid compositions on artificial joints — a systematic review of the last 10 years, Lubr. Sci. 26(2014) 387- 410. [4] H. Ghadimi, M.R. Mahmoudian and W.J. Basirun, A sensitive dopamine biosensor based on ultra-thin polypyrrole nanosheets decorated with Pt nanoparticles, Royal Society Chemistry Advances 5 (2015) 39366. [5] A. Pardo, MC. Merino, M. Mohedano, P. Casajús, AE. Coy and R. Arrabal, Corrosion behaviour of Mg/Al alloys with composite coatings, Surface and Coatings Technology 203(2009) 1252-1263. [6] F. Toptan, AC. Alves, I. Kerti, E. Ariza and LA. Rocha, Corrosion and tribocorrosion behaviour of Al–Si–Cu–Mg alloy and its composites reinforced with B 4 C particles in 0.05 M NaCl solution, Wear 306 (2013) 27-35. [7] M. AkhtariZavareh, M. Hamdi, R. RahbariGhahnavyeh, M. AmiriRoudan, M. Shafieirad, Fabrication of TiB2-TiC composites optimized by different amount of carbon in the initial Ti-BC powder mixture, Applied Mechanics and Materials 315 (2013) 720-723. [8] O. Sarikaya, S. Anik, S. Aslanlar, S.C. Okumus and E. Celik, Al–Si/B4C composite coatings on Al–Si substrate by plasma spray technique, Materials & design 28 (2007) 2443-2449. [9] Ch. Blanc and G. Mankowski, Susceptibility to pitting corrosion of 6056 aluminium alloy, Corrosion science 39 (1997) 949-959. [10] L. Lacroix, Ch. Blanc, N. Pébere, GE. Thompson, B. Tribollet, Bernard and V. Vivier, Simulating the galvanic coupling between S-Al 2 CuMg phase particles and the matrix of 2024 aerospace aluminium alloy, Corrosion Science 64 (2012) 213-221. [11] G.Y. Koga, R. Schulz, S. Savoie, A.R.C. Nascimento, Y. Drolet, C. Bolfarini, C.S, Kiminami, W.J. Botta, Microstructure and wear behavior of Fe-based amorphous HVOF coatings produced from commercial precursors, Surf. Coatings Technol. 309 (2017) 938 944.doi:10.1016/j.surfcoat.2016.10.057 [12] RE. Johnston, Mechanical characterisation of AlSi-hBN, NiCrAl-Bentonite, and NiCrAl-Bentonite-hBN freestanding abradable coatings, Surface and Coatings Technology 205 (2011) 3268-3273. [13] K. Bobzin, N. Kopp, Th. Warda, Ch. Schulz, G. Rolink and A. Weisheit, Investigation of Wear and Corrosion Protection of AlSi20 Coatings Produced by Plasma Spraying and Laser Cladding on AZ31B, Journal of thermal spray technology 22 (2013) 207-212. [14] R.Q. Guo, C. Zhang, Q. Chen, Y. Yang, N. Li, L. Liu, Study of structure and corrosion resistance of Fe-based amorphous coatings prepared by HVAF and HVOF, Corros. Sci. 53 (2011) 2351–2356. doi:10.1016/j.corsci.2010.12.022.. [15] N. Eliaz, G. Shemesh and RM. Latanision, Hot corrosion in gas turbine components, Engineering Failure Analysis 9 (2002) 31-43. [16] F. Constantin, JP. Millet, M. Abrudeanu and C. Ionescu, Corrosion Behaviour of the “Sandwich” Material AlSi/AlMn/AlSi in Contact with an Inhibited Cooling Liquid, Revista De Chimie 62 (2011) 1157-1160. [17] HY. Al-Fadhli, J. Stokes, MSJ. Hashmi and BS. Yilbas, The erosion–corrosion behaviour of high velocity oxy-fuel (HVOF) thermally sprayed inconel625 coatings on different metallic surfaces, Surface and Coatings Technology 200 (2006) 5782-5788. [18] Y. Cao, L. Du, H. Lingzhong, Ch. Chuanbing, W. Liu and W. Zhang, Wear behavior of sintered hexagonal boron nitride under atmosphere and water vapor ambiences, Applied Surface Science 257 (2011) 10195-10200. [19] F. Constantin, JP. Millet, M. Abrudeanu and C. Ionescu, Corrosion Behaviour of the “Sandwich” Material AlSi/AlMn/AlSi in Contact with an Inhibited Cooling Liquid, Revista De Chimie 62 (2011) 1157-1160. [20] S. Sampath, XY. Jiang, J. Matejicek, L. Prchlik, A. Kulkarni, and A. Vaidya, Role of thermal spray processing method on the microstructure, residual stress and properties of coatings: an integrated study for Ni–5 wt.% Al bond coats, Materials Science and
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Engineering: A 364 (2004) 216-231 [21] S. Vignesh, K. Shanmugam, V. Balasubramanian, K. Sridhar, Identifying the optimal HVOF spray parameters to attain minimum porosity and maximum hardness in iron based amorphous metallic coatings, Def. Technol. 13 (2017) 101–110. doi:10.1016/j.dt.2017.03.001. [22] AQ. Vu, B. Vuillemin, R. Oltra and C. Allély, In situ investigation of sacrificial behaviour of hot dipped AlSi coating in sulphate and chloride solutions, Corrosion Science 70(2013) 112-118. [23] H. Ghadimi, A.M.A. Salhin, N. Mohamed and S. Ghani, Electrochemical oxidation of catechol in the presence of thiosemicarbazide, Journal of The Electrochemical Society 159 (2012) E127-E131. [24] M. Yan, D.E. Tallman, and G.P. Bierwagen, Role of oxygen in the galvanic interaction between polypyrrole and aluminum alloy, Electrochimica Acta 54 (2008) 220-227. [25] A. A. Niakan, M.H. Idris, A. Ourdjini, M. Karimian, Effect of Pressure on Structure and Properties of Lost Foam Casting of Al-11Si Cast Alloy, Advanced Materials Research 110-116 (2011) 639-643. [26] M. Qian, D. Li, SB. Liu and SL. Gong, Corrosion performance of laser-remelted Al– Si coating on magnesium alloy AZ91D, Corrosion Science 52 (2010) 3554-3560. [27] PooriaMoozarm Nia, P. M. Woi, FarnazLorestani, M. R. Mahmoudian, Y. Alias, Electrodeposition of copper oxide/polypyrrole/reduced graphene oxide as a nonenzymatic glucose biosensor, Sensors and Actuators B: Chemical 209 (2015) 100-108 [28] J. Wu, J. Yang, H. Fang, S. Yoon and Ch. Lee, The bond strength of Al–Si coating on mild steel by kinetic spraying deposition, Applied surface science 252 (2006) 7809-7814. [29] N. Espallargas, Future Development of Thermal Spray Coatings, Elsevier, 2015. doi:10.1016/C2013-0-16360-X. [30] O. Sarikaya, E. Celik, S.C. Okumus, S. Aslanlar, and S. Anik, Effect on residual stresses in plasma sprayed Al–Si/B 4 C composite coatings subjected to thermal shock, Surface and Coatings Technology 200 (2005) 2497-2503.
ScienceDirect Materials Today: Proceedings 18 (2019) 5151–5157
www.materialstoday.com/proceedings
ICMPC-2019
Experimental Study of Wear Behaviour on Al-2014 Alloy Coated with Thermal Spray HVOF (High Velocity Oxy-Fuel) and Plasma Spray Process– A Review Ram Subbiaha, A.Arunb*, A.Anitha Lakshmic, A Naga Sai Harikad, N.Rame, N.Sateeshf a
Associate Professor, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad,,India b* M.Tech,, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad India c, Assistant Professor, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad, India d,e B.Tech, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad,,India F Professor, Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology,Hyderabad,,India
Abstract In this present review, wear are basic issues found in the piston. Thermal spray coatings are one of many techniques for adjustment of part's surface properties. The technology depends on the principle of melting and speeding of fine particles and their rapid solidification after effect on the substrate. Amongst all the techniques of thermal spray coatings, HighVelocity Oxy-Fuel and Plasma spray process is widely used in various applications. In this study, Al8Si20BN ceramic powder with explicit properties was selected, which was sprayed with high-speed oxygen fuels (HVOF) and plasma spray methods on aluminum alloys 2014. Both the coatings have same binder with equivalent rate. The coatings were characterizations were carried out with the help of Scanning Electron Microscope, X-ray Diffractometer, and Pin-on-disc wear testing machine. Its wear behavior was verified by the application of 5, 10, 15 and 20N loads of pins of the machine per disc, then the results of both methods were compared. According to the results, the models with HVOF coating are more durable than the models coated with plasma at different loads in a similar state. © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019 Keywords:optimization:Thermal Spray Coatings, HVOF Coating, Plasma coating, Wear resistance, Pin-On-Disc,aluminum alloys.
* Corresponding author. Tel.: +91 8801388883 E-mailaddress: [email protected]
2214-7853© 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
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R. Subbiah et al. / Materials Today: Proceedings 18 (2019) 5151–5157
1. Introduction The coating is a thin film of a material bonded to metal to include surface-specific properties, such as Resistance to oxidation or corrosion, attractive appearance, resistance to wear, color, electrical resistance or thermalProtection. The coating components were in the form thermal spraying contain alloys, ceramics, metals, composites and plastics. These coating components are used in a powder / a wire form, heated to a molten/semi molten state and from this point they are pulverized into micrometer-sized particles and accelerated to the substrate. The collection of innumerable spray particles results in the form of new coatings as described by B. Lei et al [2]. Contrary to other coating techniques, such as physical, chemical and galvanic vapor deposition, thermal spraying has a huge area with high details of the deposition ratio of M. Akhtari Zavareh et al [7]. Many forms of thermal spray coating are currently available to increase various surface properties of the metal part. HVOF thermal spraying and plasma spraying are widely used to produce wear-resistant coatings and the coating is an electrochemical process that changes the metal surface in a decorative, durable way, which increases corrosion and wear. This is the procedure in which finely isolated metallic or non-metallic materials are kept in the liquid or semi-liquid state to shape a point by point covering by M. Akhtari Zavareh et al [7]. The covering material can be a powder, a clay pole, a wire or a liquid material. This is profitable in view of its capacity to deliver a fired based covering that has a lower porosity than other generally utilized thermo test splashing forms, traditional circular segment showering or plasma showering. The aluminum silicon matrix (AlSi) is a chemically composite material that can be utiised in numerous abrasive coating systems to its great combination of wear and versatility. The silicone present in the material is practically pure, acts to increase the hardness of the coatings made of rigid materials and increases the resistance to abrasion. These properties cause immense application in several industries, as demonstrated by F. Toptan, et al. Silicon alumina is an important low-melting temperature eutectic system of B. Lei et al [2]. The conditions of dry sliding are utilized to explore the wear properties of these ceramics. 2. Materials and Processes 2.1. About Workpiece & coating powder materials The substrate was prepared of Aluminium 2014 grade alloy with the following proportions: Cu 4.62%, Fe 0.252%, Cr 0.008%, Mn0.849%, Si 0.764%, Mg 0.544%, Zn 0.094%, Ti0.041% and the remaining balance of Al (%) . The Aluminium specimens were prepared in 8 diameters x 50 mm pieces. The examples are firstly cleaned with ultrasonically in alcohol and then with acetone. Al8Si20BN powder with a 22-26μm nominal particle size was deposited. 2.2. Coating methods The most versatile coating strategy among all thermal spray systems is the plasma coating in L. Lacroix, et al [10]. A circular segment is formed between two electrodes in a plasma gas that regularly comprise of argon / helium or argon / hydrogen as a characteristic of the plasma spray apparatus. The extension and acceleration between the moulded nozzle and the creation of Mach (Ma) 2 speeds are controlled by heating the gas plasma electrode. The temperature of the plasma flow is still 17,000 ° F (9,500 ° K) within a few centimetres of the nozzle outlet, the temperature in the arc area continues to the detail of 36,000 ° F (20,000 ° K) by A. Sarhan et al [11]. Through the use of distinctive nozzle type, the elasticity of injection systems associated with the ability to create highly prepared temperatures involving the use of different coatings in plasma spray. The coatings flow from lowmelting polymers, such as nylon, to extremely high melting points, such as refractory materials including tantalum, ceramic oxides, tungsten and other refractory components. By using thermal protection, the materials will last longer and will work better at higher temperatures, which will result in a better overall system performance by N. Eliaz et al [15].
R. Subbiah et al. / Materials Today: Proceedings 18 (2019) 5151–5157
(a)
5153
Plasma spray process
(b) HVOF spray process Fig. 1: Represents the coating process of (a) Plasma spray, (b) HVOF spray.
In the plasma spray coating was performed with a plasma gun manufactured by Sulzer Metco. As shown in Fig. 1 (a) the plasma parameters used for powder spraying of Al8Si20BN are: current of 250 amps, voltage of 63 V and argon flow rate of 123.5 and 32 L / min (Ar) as gas essential and hydrogen (H2) as an optional gas separately. The spray rate is 31 g / min (4.1 lb./hour) Ag gas at a flow rate of 10.8 L / min serves as a support for infusing the plasma jet coating material. HVOF is widely used for the production of wear-resistant coatings, such as ceramic and metal mixtures, such as tungsten carbide and cobalt. In addition, HVOF can produce extremely thick coatings (with a porosity of less than 0.5%). For example, they can be used for high-tech medical instruments that are used in complex medical procedures or in simple materials in the chapter. Blancet al [9]. In this study, a HVOF thermal spray coating was performed using a Sulzer-MetcoDJ 2700 hybrid as shown in Fig. The propylene flow rate is 189 L / min, and the O2 flow rate is 345 L / min. To predict, for example, the overheating within the coating, compact air is used at a flow rate of 698 L / min to cool the sample holder until the speed of the spray gun's navigation remains stable. The particles are injected axially and centrally, the spray separation is set at 220 mm and the spray rate is 33 g / min. 2.3. Wear Tests Different types of physical tests were carried out in this segment, including porosity, density, roughness, micro hardness and joint strength, accompanied by a wear test in different loads. The hardness of the coating is calculated by coating the transverse faces using a HMV-Shimadzu device at 250g load for 13 seconds. The roughness of the coating surface (Ra) was estimated at a sum of 100 Ra points using an Alicona 3D infinity analyzer. The coated surface is institutionalized with ASTM 633 and depends on a flat circle of 1 "+ 0 / -0.005" [17]. ASTM C633 is used to calculate the strength of the coating / substrate bond. 3.
Result Analysis and Discussion
The wear test was completed with the TR-20LE with a pin-on-disk. Wear tests on uncoated and coated samples were completed using four loads. The examples were cleaned with SiC sheets at a disk speed of 180 rpm in the dry state. The speed of sliding (v = 1 m / s) and the diameter of the track (D = 40 mm) are consistent in all studies. The wear test is completed within one hour until the wear ratio of the coated examples changes and the wear rate is balanced for each individual example at a displacement distance of approximately 9108.96 m. To improve the reliability of the result, each test is processed with a similar load and a condition of five samples. After a wear test, the examples are cleaned with ultrasound with ethanol and then dried.
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(a) Plasma (b) HVOF Fig.2: AlSiBN coated samples for (a) Plasma (b) HVOF coating methods
3.1 Morphological characterization As shown in Fig. 2, the coated samples show that the coated layer provides the substrate in succession and follows well. Here the plasma coating contains numerous pores of different sizes and this porosity specifically affects wear. The sample coated with HVOF has a very dense surface. Figure 3. the surfaces of the transmission electron microscope (FESEM) in the field of samples coated with plasma and HVOF techniques in various extensions. However, during spraying, the temperature of the powder is not adequate, so that a somewhat molten area is formed in the upper part of the Al matrix as M. Yan et al [24]. Figure 3 shows several porous sections in both types of coatings. A platelet form BN dispersed in the Al matrix and pores almost interconnected in the Al-BN layer. A complete region is represented by the matrix of Al, where Si and BN are dispersed.
(a) Plasma spray process
(b) High Velocity Oxy Fuel Process
Fig. 3. at different magnifications of FESEM of Al8Si20BN coated samples: (a) 300 x, 2000 x (b) 300x, 2000 x
The silicon particles removed leave the pores as blunt points in the morphology as described by Bobzin et al. (2012) [13]. HVOF coatings are denser than plasma coatings. Johnston et al. [12]. This is due to the impact of rapid particle coatings, resulting in a high quality durable individual signs and a high thickness by A. A. Niakan et al. [25] As a result of the charge created during rapid hardening, cracks and pores are formed vertically in the plates. In general, homogeneous coatings without insulation are essential to increase erosion and block wear of the coating by J. Wu et al [28]. In fig. 3. (a, b), porosity and pore size in plasma samples are significantly greater than in samples coated with HVOF. 4. Wear Behaviour The two coated samples with plasma and HVOF were achieved a normal micro hardness of 160 and 210 HV separately. The hardness in the SiBN area is higher and lower in the aluminum area. And the density of the coating straightly affects the hardness of the coating, so the hardness of the HVOF test is greater than that of the plasma layer. As indicated by Bobzin et al. [13], the normal micro hardness of this chemical composition covered by the plasma technique is approximately 156 HV. Rolink et al. It has also been shown that the micro hardness of Al20 Si is approximately 147 HV of J. Wu et al [28].
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Regarding the application, it is important that M. Qian et al [26] apply the strength of the bond between the coated layer and the useful life of the coating. The examples in this research work were coated to accomplish a high elasticity (binding). The study of the binding strength of the samples showed that the plasma binding strength of 1600-2100 Psi was lower than the HVOF with 1900-2800 Psi. by the results of Wu et al. (2006) [20]. The roughness values of the samples coated with plasma and HVOF are 3.8 and 4.6 μm individually. As the roughness results show, the samples with HVOF coating are thicker than the plasma. The wear resistance of a smooth surface decreases from HY. Al-Fadhli et al [17]. Figure 4. shows FESEM images of carbon steel samples with extreme loads (20 N). Figure 4. (a) shows a noticeable crack that ends with deformation after being loaded at the end of the substrate surface. In fig. 4. (b) It is obvious that carbon steel shows that it is worn. At the end of the wear test, profound and wide notches are shaped superficially, and traces of wear are obvious on the whole surface.
(a) FESEM-800x
(b) FESEM-500x Figure. 4. FESEM images for carbon steel samples at load (20 N)
(c) FESEM-7000x
These traces of wear are with the pin on disc device during wear test. According to fig. 4. (c), the larger increase neatly shows the worn surface of the steel sample and wear residue. This study means that due to the surprisingly high loading on the sample, the surface of the steel has lost a detectable measure of the parts. The surface is rough as a result of wear of the residue. Figure 5 shows FESEMs of residual wear in Al8Si20BN plasma and samples coated with HVOF at load (20 N). As shown in FIG. 5 (a, b), the pins of the sample coated with plasma are lighter than the HVOF in Fig. 5 (c, d). In addition, the rate of removal of material from the sample surface of the plasma layer is significantly higher than that of the sample with HVOF.This conception indicates that this pile is excessively high for the sample coated with plasma. The proximity of the cavities in the plasma coating further aggravated the accident of the coating of J. Wu, J. Yang, et al. [28]
(a) FESEM-500X
(b) FESEM-1000X
(c) FESEM-500X
(d) FESEM-1000X
Figure.5 FESEM for the ear of sample residues coated with Al8Si20BN at load (20 N) for (a), (b) Plasma coating, and (c), (d) HVOF coating
Therefore, the plasma coating has a lower resistance to wear due to the Maximum load is applied, the surface of the sample is more worn than the HVOF sample and the trace of the pins is obvious. This is mainly due to the abundant surface porosity of M. Yan et al [24]
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In addition, Lei et al. (2014) [16] specify that a delicate matrix rich in aluminum disappears quickly, but solid SiBN particles slow down the wear process. This is related to the increase in the strength of the link between the characters and the component, as well as to the important role that the binding force of propagation and protection of the sign can have since the beginning of a break of Y.Cao et al [18]. The FESEM of the plasma-coated coatings of Fig. 5 (a, b), the deposits formed by partially molten droplets and the coated samples have a specific amount of porosity. In fig. 5 (c, d), there was an insignificant probability of SiBN in the aluminum matrix of the HVOF spray coating since this matrix contained the SiBN particles in a categorical manner and the deposited layer was extremely thick by J. Wu et al.[28]. The standards for normal wear and weight reduction for carbon steel and plasma-coated samples and HVOF, respectively, below 5, 10, 15 and 20 N load. 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