Effects of Y_2O_3 on the microstructure and wear resistance of cobalt-based alloy coatings deposited by plasma transferred arc process

Cobalt-based alloys with different Y2O3 contents were deposited on Q235A-carbon steel using plasma transferred arc （PTA） welding machine. The effect of Y2O3 on the microstructure and wear resistance properties of the cobait-based alloys were investigated using an optical microscope, a scanning electron microscope （SEM）, X-ray diffraction （XRD）, and transmission electron microscopy （TEM）. It was found that a cobalt-based solid solution with a face-centered cubic crystal structure was presented accompanied by the secondary phase M7C3 with a hexagonal crystal structure in the Y2O3-free cobalt-based alloy coating. Several stacking faults exist in the cobalt-based solid solution. The addition of Y2O3 leads to the existence of the Y2O3 phase in the Y2O3-modified coatings. Though stacking fault exists in the Y2O3-modified coatings, its density increases. The addition of Y2O3 can refine the microstructure and can increase the wear resistance properties when its contents are less than or equal to 0.8 wt.%. However, further increase of its contents will lead to the agglomeration of undissolved Y2O3 particles at the γ-Co grain boundary, and will lead to a coarse microstructure and lower wear resistance properties.

Parameter optimization for tungsten carbide/Ni-based composite coating deposited by plasma transferred arc hardfacing

Ni-based composite coatings with a high content of tungsten carbides(Stelcar65composite coatings)were synthesized by plasma transferred arc(PTA)hardfacing.The welding parameters of Stelcar65composite coatings were optimized by orthogonal tests.The PTA welding parameters including welding current,powder feed rate and welding speed have significant influence on the tungsten carbide degradation.The values for the optimum welding current,powder feed rate and welding speed were determined to be100A,25g/min and40mm/min,respectively.The produced WC/Ni-based composite coatings were crack-and degradation-free.The microstructure of deposited layers,as well as the microstructure and microhardness of the optimal coating were further analyzed.

Numerical Modeling of the High-Intensity Transferred Arc with a Water-Cooled Constrictor Tube

Stable and axi-symmetrical DC high-intensity transferred arcs with a coaxial water-cooled constrictor tube have been used to study the arc characteristics for many years. All the previous modeling studies concerning the high-intensity transferred arcs were restricted to the near-anode region. Modeling results are presented in this paper concerning the characteristics of the whole high-intensity transferred arc, referring to a recent experiment. It is shown that the computed flow and temperature fields for different flow rates of the working gas are overall similar, but a fully developed flow regime can only be achieved in the water-cooled constrictor tube at low working-gas flow rates. The predicted radial profiles of plasma temperature at the cross section near the constrictor-tube exit compare favorably with available experimental data, but corresponding comparison about the plasma axial-velocity profiles shows appreciable difference, revealing that there may exist considerable errors in the plasma velocity measurements using a sweeping Pitot tube.

Influences of the microstructure on the wear resistance of cobalt-based alloy coatings obtained by plasma transferred arc process

The microstructure, substructure, and wear characteristic of cobalt-basedalloy coatings obtained by plasma transferred arc (PTA) process were investigated using opticalmetallurgical microscope, X-ray diffraction (XRD), scanning electron microscope (SEM), transmissionelectron microscope (TEM), and dry sand abrasion tester (DSAT). The aging effect on the structureand wear resistance of the cobalt-based PTA coating was also studied. The results show that theas-welded coating consists of cobalt-based solid solution with face-centered cubic structure andhexagonal (Cr,Fe)_7C_3. There are a lot of stacking faults existing in the cobalt-based solidsolution. After aging at 600 deg C for 60 h, the microstructure becomes coarse, and another carbide(Cr,Fe)_(23)C_6 precipitates. As a result, the wear mass loss of the aged sample is higher than thatof the as-welded sample.

Research on droplet transfer in oscillating arc narrow gap GMA welding

In this paper, the droplet transfer in oscillating arc narrow gap gas metal arc （ GMA ） welding was studied. According to the experimental results, the oscillating arc has effect on the droplet transfer mode. The droplet transfer frequency in narrow gap groove is higher than that in bead-on-plate welding. Because of the change of arc location in narrow gap groove, the droplet transfer in oscillating arc narrow gap changes regularly. The droplet transfer frequency near groove sidewall is higher than that at the middle of narrow gap groove.

Corrosion Behavior of Plasma Transferred Arc Fe-based Coating Reinforced by Spherical Tungsten Carbide in Hydrochloric Acid Solutions

Fe-based coatings reinforced by spherical tungsten carbide were deposited on 304 stainless steel using plasma transferred arc(PTA) technology.The composition and phase microstructure of the coatings were evaluated using scanning electron microscopy(SEM),energy dispersive spectrometer(EDS) and X-ray diffraction(XRD).The corrosion behaviors of the coatings in 0.5 mol/L HCl solution were studied using polarization curve and electrochemical impedance spectroscopy(EIS) measurements.The experimental results shows that the tungsten carbide improves the corrosion resistance of the Fe-based alloy coating,but increase in the mass fraction of tungsten carbide leads to increasing amount of defects of holes and cracks,which results in an adverse effect on the corrosion resistance.The defects are mainly present on the tungsten carbide but also extend to the Fe-based matrix.The tungsten carbide,acting as a cathode,and binding material of Fe-based alloy,acting as an anode,create a galvanic corrosion cell.The binding material is preferentially corroded and causes the degradation of the coating.

Microstructure and properties of TiN/Ni composite coating prepared by plasma transferred arc scanning process

The TiN/Ni composite coatings were deposited on 7005 aluminium alloy by high speed jet electroplating and then processed with plasma transferred arc(PTA)scanning process.The microstructure,microhardness and friction coefficient of PTA scanning treated specimens were investigated.It is shown that the PTA scanning treated specimens have a rapidly solidified microstructure consisting of the uniformly distributed TiN phase and fine Al3Ni2 intermetallic phases.The composite coating has an average microhardness of approximately HV 800.The friction coefficient of PTA scanning treated specimens(oscillated at around 0.25)is considerably lower than that of TiN/Ni composite coating(oscillated at around 0.35).The corrosion behavior of the composite coating in 3.5%NaCl solution at room temperature was also determined using a potentiostat system.In comparison with the corrosion potentialφcorr of-0.753 V for 7005 aluminium alloy,the corrosion potentials for TiN/Ti composite coating and PTA scanning treated specimen are increased by 0.148 V and 0.305 V,respectively.The PTA scanning treated specimen has the lowest corrosion current density Jcorr as well as the highest corrosion potentialφcorr,showing an improved corrosion resistance compared with 7005 aluminium alloy.

Research on arc characteristics and metal transfer modes of ultrasonic assisted GMAW process

Ultrasonic assisted GMAW （U-GMAW） method is a novel process, which combines the ultrasonic wave with gas metal arc welding to improve the process stability and weld quality. The U-GMAW system is developed and the ultrasonic wave is applied by means of acoustic radiation. The arc characteristics and metal transfer modes are studied in comparison with conventional GMAW process. The arc plasma is compressed and the arc length is shorter than that in conventional GMAW process after the ultrasonic is applied onto the arc. The parameter range of short-circuiting mode is extended and the range of unstable transfer is minimized. The changes in arc characteristics are responsible for changes in metal transfer modes.

Modelling Study on the Plasma Flow and Heat Transfer in a Laminar Arc Plasma Torch Operating at Atmospheric and Reduced Pressure

A modelling study is performed to investigate the characteristics of both plasma flow and heat transfer of a laminar non-transferred arc argon plasma torch operated at atmospheric and reduced pressure. It is found that the calculated flow fields and temperature distributions are quite similar for both cases at a chamber pressure of 1.0 atm and 0.1 atm. A fully developed flow regime could be achieved in the arc constrictor-tube between the cathode and the anode of the plasma torch at 1.0 atm for all the flow rates covered in this study. However the flow field could not reach the fully developed regime at 0.1 atm with a higher flow rate. The arc-root is always attached to the torch anode surface near the upstream end of the anode, i.e. the abruptly expanded part of the torch channel, which is in consistence with experimental observation. The surrounding gas would be entrained from the torch exit into the torch interior due to a comparatively large inner diameter of the anode channel compared to that of the arc constrictor-tube.

Study of the Material Transfer Characteristics and Surface Morphology Due to Arc Erosion of PtIr Contact Materials

By means of breaking tests on PtIr contact materials via a JF04C contact material testing machine, it was attempted to elucidate the characteristics of the various surface morphology and material transfer after the arc erosion process caused by break arc. The material transfer characteristics appeared in the experiments were concluded and analyzed. Meanwhile, the morphology of the anode and cathode surface were observed and analyzed by SEM.

Wear Properties of Plasma Transferred Arc Fe-based Coatings Reinforced by Spherical WC Particles

Fe-based coatings reinforced by spherical WC particles were produced on the 304 stainless steel by plasma transferred arc(PTA) to enhance the surface wear properties. Three different Fe/WC composite powder mixtures containing 0 wt%, 30 wt%, and 60 wt% of WC were investigated. The microstructure and phase composition of the Fe/WC composite PTA coatings were evaluated systemically by using scanning electron microscope(SEM) and X-ray diffraction(XRD). The wear properties of the three fabricated PTA coatings were investigated on a BRUKER UMT TriboLab. The morphologies of the worn tracks and wear debris were characterized by using SEM and 3 D non-contract profiler. The experimental results reveal that the microhardness on the cross-section and the wear resistance of the fabricated coatings increase dramatically with the increasing adding WC contents. The coating containing 60 wt% of WC possesses excellent wear resistance validated by the lower coefficients of friction(COF), narrower and shallower wear tracks and smaller wear rate. In the pure Fe-based coating, the main wear mechanism is the combination of adhesion and oxidative wear. Adhesive and two-body abrasive wear are predominated in the coating containing 30 wt% of WC, whereas threebody abrasion wear mechanism is predominated in the coating containing 60 wt% of WC.

MATHEMATICAL SIMULATION OF HEAT AND MASS TRANSFER IN PULSED ARC WELDING BY MELTING ELECTRODE

In this paper the processes of melting and transfer of an electrode metal to the molten pool, hydrody- namics of molten pool in controlled pulsed arc welding in carbon dioxide have been investigated.The process of pulsed arc welding with systematic short - circuits of the arc gap is realized by adaptive algo- rithms of pulsed control over main energetic parameters of welding - arc current and voltage,arc heated efficiency,peak,short - circuiting current, which provide the dosage of energy for energy for melting and transfer of every for of an electrode metal, the control over fluidity of the weld pool. Physica and mathematical models describing such processes in CO2, origind software hare been developed.The re- sults of physical simulation and mathemaical modelling permit to determine the influence of energetic parameters of the process on the condition of the 'power source-electrode-arc-molten pool' electrodynamic system at each moment of time.

Study on arc characteristics and behavior of metal transfer in pulse current flux-cored arc welding of mild steel

The variation in arc characteristics and behavior of metal transfer with the change in pulse parameters has been studied by high speed video camera during pulse current flux-cored arc weld deposition.A comparative study of similar nature has also been carried out during flux-cored arc weld deposition in globular and spray transfer modes.The effect of pulse parameters has been studied by considering their mean current and arc voltage.The arc characteristics studied by its root diameter,projected diameter and length,and the behavior of metal transfer noted by the metal transfer model and the droplet diameter have been found to vary significantly with the pulse parameters.The observation may help in understanding the arc characteristics with respect to the variation in pulse parameters which may be beneficial in using pulse current FCAW to produce desired weld quality.

Comparisons of particles thermal behavior between Fe-base alloy and boron carbide during plasma transferred-arc powder surfacing

Comparisons of particle’s thermal behavior between Fe base alloy and boron carbide in plasma transferred arc (PTA) space was made based on theoretical evaluation results in this article. It was found that most of the Fe base particles would be fully melted while they transporting through the central plasma field with 200 A surfacing currents. And the particles with a diameter less than 0.5×10 -4 m might be fully evaporated. However, for the boron carbide (B 4C) particles, only the one with a diameter less than 0.5×10 -4 m could be melted in the same PTA space. Most of B 4C particles are only preheated at its solid state when they were fed through the central field of PTA plasma when the surfacing current is equal to or less than 200 A . When the arc current was smaller than100 A , only the particles smaller than 0.5×10 -4 m could be melted in the PTA space for the Fe base alloy. Almost none of the discussed B 4C particles could be melted in the 100 A PTA space.

Fabrication of in-situ TiC reinforced composite coating via plasma transferred arc process

In this work, the in-situ TiC panicles reinforced composite coating was prepared by plasma transferred arc process on the surface of Q235 steel. Microstructures, phase composition and wear property of the coating were investigated. The results showed that the composite coating consisted mainly of T-Ni, TiC, Cr23C6, Cr7C3, Ni3Si, CrB, Cr5B3 and FeNi3 phases, and was characterized by fine TiC panicles embedded in Ni matrix. The wear resistance of composite coating was significantly improved compared with that of the steel substrate. The wear volume loss of the substrate was 443 mm3, which was about 9 times as that of in-situ TiC particles reinforced composite coating （49 mm3 ）. It is mainly attributed to the presence of chromium carbide particles and in-situ TiC particles and their favorable combination with Ni matrix.

Behavior of an indigenously fabricated transferred arc plasma furnace for smelting studies

The utilization of industrial solid waste for metal recovery requires high-temperature tools due to the presence of silica and alumina, which is reducible at high temperature. In a plasma arc furnace, transferred arc plasma furnace（TAP） can meet all requirements, but the disadvantage of this technology is the high cost. For performing experiments in the laboratory, the TAP was fabricated indigenously in a laboratory based on the different inputs provided in the literature for the furnace design and fabrication. The observed parameters such as arc length, energy consumption, graphite electrode consumption, noise level as well as lining erosion were characterized for this fabricated furnace. The nitrogen plasma increased by around 200 K（200 ℃） melt temperature and noise levels decreased by ~10 d B compared to a normal arc.Hydrogen plasma offered 100 K（100 ℃） higher melt temperature with ~5 d B higher sound level than nitrogen plasma. Nitrogen plasma arc melting showed lower electrode and energy consumption than normal arc melting, whereas hydrogen plasma showed lower energy consumption and higher electrode consumption in comparison to nitrogen plasma. The higher plasma arc temperature resulted in a shorter meltdown time than normal arc with smoother arcing. Hydrogen plasma permitted more heats, reduced meltdown time, and lower energy consumption, but with increased graphite consumption and crucible wear. The present study showed that the fabricated arc plasma is better than the normal arc furnace with respect to temperature generation, energy consumption, and environmental friendliness. Therefore, it could be used effectively for smelting-reduction studies.

Computer-based sensing and visualizing of metal transfer mode in gas metal arc welding

Using Xenon lamp lights to overcome the strong interference from the welding arc, a computer-based system is developed to sense and visualize the metal transfer in GMAW. This system combines through-the-arc sensing of the welding current and arc voltage with high speed imaging of the metal transfer. It can simultaneously display the metal transfer processes and waveforms of electrical welding parameters in real-time The metal transfer videos and waveforms of electrical welding parameters can be recorded. Metal transfers under various welding conditions have been investigated with the system developed.

Effect of pulse M-Arc frequency on Tri-Arc DE droplet transfer and weld forming

In view of the unstable welding process of Tri-Arc DE,surfacing test with Q235 steel plate was completed with the help of the self-built high-speed camera and waveform synchronous acquisition system using the Tri-Arc DE technology. The effects of pulsed M-Arc frequency on Tri-Arc DE droplet transfer and weld formation were analyzed. The results show that while the gradual increase of pulse frequency,the droplet transfer frequency gradually decreases,which is followed by several drops per pulse,one drop per pulse,and one drop within several pulses. The most ideal transfer form is one drop per pulse,of which the welding process is the most stable,and the quality of weld formation is the most satisfied.

Numerical simulation of constricted and diffusive arc–anode attachments in wall-stabilized transferred argon arcs

A numerical simulation is conducted to investigate arc-anode attachment behavior, especially the formation mechanism of the constricted arc attachment mode for the water-cooled anode of wall-stabilized transferred argon arcs. Argon molecular ions and the corresponding kinetic processes are included to the finite-rate chemistry model in order to capture the chemical nonequilibrium characteristics of the arc near the anode region. Modeling results show that constricted and diffusive arc–anode attachments can be self-consistently obtained at different arc currents while keeping other parameters unchanged. The dominant kinetic processes contributing to ionization and recombination in the arc center and fringes are presented. The results show that in arc fringes and the arc attachment region, molecular ion recombination plays an important role which leads to the rapid loss of electrons. The radial evolution of the production, loss and transport processes of electrons is further analyzed. It is found that for the constricted arc attachment mode, both the recombination and convection transport caused by the anode jet result in the loss of electrons at the arc fringes, which leads to the shrinkage of the arc column at the anode. The formation of the anode jet is due to the combined action of radial and axial Lorentz forces in the anode region.

The theoretical evaluation of powders transportation in plasma transferred-arc space under coaxial powder feeding condition

The powders transportation in the plasma transferred-arc space during the coaxial powder-feeding surface depositing process was theoretical evaluated. The axial acceleration and velocity of various particles in the arc column were described. According to the results from theoretical calculations, it was found that: (1) The powder’s transporting velocity is much lower than the plasma fluid’s; (2) The powders axial transporting velocity presents “valley-shape distribution” along plasma arc column traverse section when surfacing current is greater than 100 A . When the arc current exceeding 100 A , the powders coming through the center field of arc column will transport slower than the powder through the outer-around field of arc column. It is in the field where the temperature is in the range of 9 000 K ～11 000 K that the particles can achieve its maximum axial acceleration in the argon plasma space. (3) For the given powder mass density, the smaller its size is, the greater its acceleration and the greater its averaged transporting velocity will be in the arc space; (4) For the given powder size, the greater its mass density is, the smaller its acceleration and averaged velocity will be in the arc space.