Tribological properties of nanostructured Al_2O_3-40%TiO_2 multiphase ceramic particles reinforced Ni-based alloy composite coatings

The Ni-based alloy composite coatings reinforced by nanostructured Al2O3-40%TiO2 multiphase ceramic particles were prepared on the surface of 7005 aluminum alloy by plasma spray technology. The microstructure and tribological properties of the composite coatings were researched. The results show that the composite coatings mainly consist of γ-Ni, α-Al2O3, γ-Al2O3 and rutile-TiO2 etc, and exhibit lower friction coefficients and wear losses than the Ni-based alloy coatings at different loads and speeds. The composite coating bears low contact stress at 3 N and its wear mechanism is micro-cutting wear. As loads increase to 6-12 N, the contact stress is higher than the elastic limit stress of worn surface, and the wear mechanisms change into multi-plastic deformation wear, micro-brittle fracture wear and abrasive wear. With the increase of speeds, the contact temperature of worn surface increases. The composite coating experiences multi-plastic deformation wear, fatigue wear and adhesive wear.

Fabrication of in-situ synthesized ceramic reinforced Ni-based alloy composite coatings by reactive braze coating processing

In-situ synthesized ceramic such as TiC,Cr7C3 and Cr5B3 reinforced Ni-based alloy composite coating was fabricated on the surface of mild steel substrate by reactive braze coating processing with colloidal graphite,Cr,Ni,ferro-boron,Si and titanium powders as the raw materials at low temperature of 1000℃,and a new kind of coating materials was developed.By means of SEM,EDS,XRD and surface hardness tester,the microstructures,phases,hardness and wear-resistance of the coating were analyzed,respectively.The results revealed that the coating was mainly composed of the ceramic in-situ synthesized reinforcement phases of TiC,Cr7C3 and Cr5B3 and the binder phases in-situ synthesized of Ni31Si12 and(Ni,Fe)solid solution;The ceramic reinforcement phases of TiC,Cr7C3 and Cr5B3 were randomly distributed in the binder phases of Ni31Si12 and(Ni,Fe)solid solution;The coating had about 15vol%pores and can possibly be applied as a self-lubrication coating;The coating and the substrate were integrated together by metallurgical bonding;The coating had a hardness up to 91-94HR15N.

Microstructure and bonding strength of Ni-based alloy coating

A Ni-Cr-B-Si coating technique was developed and successfully applied on austenite grey iron substrate in a conventional resistance furnace under graphite powder protection. The microstructure, phase distribution, chemical composition profile and microhardness along the coating layer depth were investigated. Shear strength of the coating was also tested. Microanalysis shows that the coating is consist of γ-Ni solution and γ-Ni+Ni3B lamellar eutectic, as well as small amount of Cr5B3 particles. Diffusion induced metallurgical bonding occurs at the coating/substrate interfaces, and the higher the temperature, the more sufficient elements diffused, the broader interfusion region and the larger bonding strength, but it has an optimum value. And the bonding strength at the interface can be enable to reach 250-270 MPa, which is nearly the same as that of processed by flame spray. The microhardness along the coating layer depth shows a gradient distribution manner.

Tribological properties of Ni-base alloy composite coating modified by both graphite and TiC particles

In order to reduce the friction coefficient of Ni-base alloy coating and further improve its wear resistance,Ni-base alloy composite coatings modified by both graphite and TiC particles were prepared by plasma spray technology on the surface of 45 carbon steel.The results show that friction coefficient of the composite coating is 47.45% lower than that of the Ni-base alloy coating,and the wear mass loss is reduced by 59.1%.Slip lines and severe adhesive plastic deformation are observed on the worn surface of the Ni-base alloy coating,indicating that the wear mechanisms of the Ni-base alloy coating are multi-plastic deformation wear and adhesive wear.A soft transferred layer abundant in graphite and ferric oxide is developed on the worn surface of the composite coating,which reduces the friction coefficient and wear loss in a great deal.The main wear mechanism of the composite coating is fatigue delamination of the transferred layer.

Tribological behavior and mechanisms of graphite/CaF_2/TiC/Ni-base alloy composite coatings

In order to reduce the friction coefficients and improve the wear resistance of mechanical parts, which work in the severe friction and wear conditions at heavy loads, the graphite/CaFg/TiC/Ni-base alloy composite coatings were prepared by plasma spray and their tribological behavior and mechanisms were investigated. The results show that the friction coefficients of the composite coatings are in the range of 0.22-0.288, which are reduced by 25.9% to 53% compared with those of the pure Ni-base alloy coatings, and the wear rates of the former are 18.6%-70.1% less than those of the latter. When wear against GCr15 steel balls, a transferred layer mainly composed of ferric oxides, graphite and CaF2 may gradually develop on the worn surface of the composite coatings, which made the friction and wear between GCr15 steel ball and the composite coatings change into that between the former and the transferred layer. So the friction coefficients and the wear lubrication effect of the transferred layer. The main wear layer in friction process. rates of the composite coatings are greatly reduced because of the solid mechanism of the composite coatings is delamination of the transferred

Effects of graphite content on microstructure and tribological properties of graphite/TiC/Ni-base alloy composite coatings

In order to reduce the friction coefficients and further improve the anti-wear properties of Ni-base alloy coatings reinforced by TiC particles,graphite/TiC/Ni-base alloy（GTN） coatings were prepared on the surface of 45 carbon steel.The effects of graphite content on the microstructure and tribological properties of the GTN coatings were investigated.The results show that the addition of graphite to the GTN coatings may greatly reduce the friction coefficients and improve their wear resistance.The 6.56GTN and 12.71GTN coatings exhibit excellent integrated properties of anti-friction and wear resistance under low and high loads,respectively.Under a low load,the wear mechanisms of the GTN coatings are mainly multi-plastic deformation with slight abrasive wear and gradually change into mixture of multi-plastic deformation,delamination and micro-cutting wear with the increase of graphite fraction.As the load increases,the main wear mechanisms gradually change from micro-cracks,micro-cutting and adhesive wear to micro-cutting and micro-fracture with the increase of graphite fraction.

Tribological properties and wear prediction model of TiC particles reinforced Ni-base alloy composite coatings

TiC particles reinforced Ni-based alloy composite coatings were prepared on 7005 aluminum alloy by plasma spray. The effects of load, speed and temperature on the tribological behavior and mechanisms of the composite coatings under dry friction were researched. The wear prediction model of the composite coatings was established based on the least square support vector machine (LS-SVM). The results show that the composite coatings exhibit smaller friction coefficients and wear losses than the Ni-based alloy coatings under different friction conditions. The predicting time of the LS-SVM model is only 12.93%of that of the BP-ANN model, and the predicting accuracies on friction coefficients and wear losses of the former are increased by 58.74%and 41.87%compared with the latter. The LS-SVM model can effectively predict the tribological behavior of the TiCP/Ni-base alloy composite coatings under dry friction.

纳米或超细WC-Co粉体制备过程强化研究进展

【目的】总结纳米或超细碳化钨钴(WC-Co)粉体制备过程的研究,解决WC-Co做为热喷涂原料对机械零件的磨损和腐蚀的影响。【研究现状】总结纳米或超细WC-Co制备过程强化、反应路径,以及Co对还原碳化过程的作用等;其中机械作用力强化包括球磨强度的影响、氧化钨原料的影响、反应温度的影响,原子或分子水平强化包括气相化学合成、喷雾转化,气相碳质强化反应过程包括烃类物质、一氧化碳;纳米或超细WC-Co制备过程反应路径包括还原过程、碳化过程;对还原碳化过程的作用包括Co对氧化钨还原碳化过程具有催化作用、Co影响WC-Co产物粒径、Co含量增加降低碳化温度、Co促进气态碳源析碳等。【结论与展望】提出WC-Co粉体制备反应路径方面,应深入揭示制备反应路径,应进一步分析缺碳相η物相在制备过程中的作用,对W、Co、C扩散的影响机制;认为模拟分析反应过程中还原碳化气与固体原料之间的热量、质量传递过程,可为制备过程进一步优化调控和反应器放大设计奠定理论基础;同时WC-Co粉体热喷涂性能方面,用于机械件的喷涂处理时,应测试涂层的抗磨损和腐蚀性能,反馈调控优化和制备过程。

Wear resistance of Zr/WC composite coatings on Cr12MoV steel surface by electric spark deposition

Zr/WC composite coating was prepared on the surface of Cr12MoV steel by electric spark deposition technology to change its surface properties. The surface and worn surface morphology of the coating were observed using scanning electron microscope. Dry friction and wear tests of the coatings were carried out at room temperature. The results show that the coating is continuous and uniform, and the thickness was about 50-60 μm. The microhardness of the coating surface was highest at 1140 HV_(200g), which was significantly higher than that of the substrate. The ear tests results show that the wear weight loss, wear volume and wear rate follow the following rules: Cr12MoV>WC coating> Zr/WC composite coating.

Microstructure,microhardness and corrosion resistance of laser cladding Ni−WC coating on AlSi5Cu1Mg alloy

The microstructure,microhardness,and corrosion resistance of laser cladding Ni−WC coating on the surface of AlSi5Cu1Mg alloy were investigated by scanning electron microscopy,X-ray diffraction,microhardness testing,immersion corrosion testing,and electrochemical measurement.The results show that a smooth coating containing NiAl,Ni_(3)Al,M_(7)C_(3),M_(23)C_(6)phases(M=Ni,Al,Cr,W,Fe)and WC particles is prepared by laser cladding.Under a laser scanning speed of 120 mm/min,the microhardness of the cladding coating is 9−11 times that of AlSi5Cu1Mg,due to the synergistic effect of excellent metallurgical bond and newly formed carbides.The Ni−WC coating shows higher corrosion potential(−318.09 mV)and lower corrosion current density(12.33μA/cm^(2))compared with the matrix.The crack-free,dense cladding coating obviously inhibits the penetration of Cl^(−)and H^(+),leading to the remarkedly improved corrosion resistance of cladding coating.

Wear characteristics of spheroidal graphite roll WC-8Co coating produced by electro-spark deposition

Electro-spark deposition（ESD） was adopted for preparing high property coatings by depositing WC-8Co cemented carbide on an spheroidal graphite roll substrate.The microstructure and properties of the coating were investigated by X-ray diffraction（XRD）, scanning electron microscopy（SEM） with energy dispersive X-ray（EDX） and ball-disc configuration wear tester.The results show that nanosized particles and amorphous structures prevail in the coating which is metallurgically bonded to the substrate.The microstructures of the transition zone include columnar structure and equiaxed structure.The primary phases of the coating contain W2C, W6C2.54, Fe3W3C, and Co3W3C.The results of abrasive test show that the coating has low friction coefficients（μaverage = 0.18） and the wear mechanisms are mainly abrasive wear, fatigue wear, and oxidation wear.The maximum microhardness value of the coating is about 17410 N/mm2.The study reveals that the electro-spark deposition process has better coating quality and the coating has high wear resistance and hardness.

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

To prepare high wear resistance and high hardness coatings, electro-spark deposition was adopted for depositing an electrode of a mixture of 92wt%WC＋8wt%Co on a cast steel roll substrate. The coating was characterized by classical X-ray diffractometer （XRD） and scanning electron microscopy （SEM） with energy dispersive X-ray analysis （EDX）. The results indicate that the coating shows nanosized particulate structure and dendritic structure including columnar structure and equiaxed structure. The primary phases of the coating contain Fe3W3C, Co3W3C, Fe2C and Si2W. The coating has a low friction coefficient of 0.13, its average wear-resistance is 3.3 times that of the cast steel roll substrate and the main mechanism is abrasive wear. The maximum microhardness value of the coating is about 1573.9 Hv0.3. The study reveals that the electro-spark deposition process has the characteristic of better coating quality and the coating has higher wear resistance and hardness.

Study on GNi-WC25 Coating by High Frequency Induction Cladding

Process and mechanism of high frequency were studied in this paper by means of cold attachment for the preparation of GNi WC25 coating . The results show its special distribution law of eddy current while the magnetic transition temperature and electric resistivity of the coating have been measured .Wear resistance of the high frequency induction coating has an advantage over those of laser cladding coating and oxygen acetylene spraying fusing coating . Moreover , the GNi WC25 coating by high frequency induction cladding has smooth surface and even microstructure.

Thermal sprayed WC-Co coatings and their mechanical properties

HVOF thermal spraying tests were carried out for thermal spraying the coatings with two kinds of cermet powders,which are microstructured Sulzer Metco Diamalloy 2004 WC-12%Co powders and nanostructured WC-12%Co powders.The microstructures of the as-prepared WC-12%Co coatings were then characterized by using XRD analyzer and SEM.The mechanical properties of the two coatings were evaluated by microhardness test,bend test,cup test,tensile test and abrasive wear test.The results showed that the mechanical properties of WC-12%Co coatings sprayed with nanostructured WC-12%Co powder is higher than that of coatings sprayed with microstructured WC-12%Co powders,and the reasons were discussed.

Influence of Heat Treatment on Microstructure and Sliding Wear Behavior of Fe-Al/WC Composite Coatings

An experimental study has been carried out to investigate the influence of heat treatment at 300 ℃,450 ℃,550 ℃,650 ℃ and 800 ℃ on the microstructure and sliding wear behavior of Fe Al/WC intermetallic composite coatings produced by high velocity arc spraying (HVAS) and cored wires. The result shows, the main phases in both as sprayed and heat treated Fe Al/WC composite coatings are iron aluminide intermetallics (Fe 3Al+FeAl) and α as well as a little oxide (Al 2O 3) and carbides (WC, W 2C, Fe 2W 2C and Fe 6W 6C). After heat treated at 450-650 ℃, dispersion strengthening of Fe 2W 2C and Fe 6W 6C will lead to a rise in microhardness of the coatings. The microhardness is likely to be the most important factor which influences the sliding wear behavior of the coatings. Increasing the microhardness through heat treatment will improve the sliding wear resistance of the Fe Al/WC composite coatings.

Structure of Micro-nano WC-10Co4Cr Coating and Cavitation Erosion Resistance in NaCl Solution

Cavitation erosion （CE） is the predominant cause for the failure of overflow components in fluid machinery. Advanced coatings have provided an effective solution to cavitation erosion due to the rapid development of surface engineering techniques. However, the influence of coating structures on CE resistance has not been sys- tematically studied. To better understand their relationship, micro-nano and conventional WC-10Co4Cr cermet coat- ings are deposited by high velocity oxygen fuel spray- ing（HVOF）, and their microstructures are analyzed by OM, SEM and XRD. Meanwhile, characterizations of mechan- ical and electrochemical properties of the coatings are carried out, as well as the coatings＇ resistance to CE in 3.5 wt % NaC1 solution, and the cavitation mechanisms are explored. Results show that micro-nano WC-10Co4Cr coating possesses dense microstructure, excellent mechanical and electrochemical properties, with very low porosity of 0.26 4-0.07% and extraordinary fracture toughness of 5.58 4-0.51 MPa.m1/2. Moreover, the CE resistance of micro-nano coating is enhanced above 50% than conventional coating at the steady CE period in 3.5 wt % NaC1 solution. The superior CE resistance of micro- nano WC-10Co4Cr coating may originate from the unique micro-nano structure and properties, which can effectively obstruct the formation and propagation of CE crack. Thus,a new method is proposed to enhance the CE resistance of WC-10Co4Cr coating by manipulating the microstructure.

Influence of Interfacial Diffusion on Mechanical Property of Vacuum Fusion Sinter (VFS) WC-Co Composite Coating

The WC-Co composite coatings bonded tightly to steel substrate have been made by vacuum fusion sinter （VFS）. The concentration distribution of some components were measured by the electron probe, and the microstructure and morphology of VFS coatings were observed and analyzed by SEM, X-ray diffractometer and microhardness tester. Diffusion coefficient of every element was calculated by using the experimental results. The influence of the interracial diffusion on the microstructure, Vickers hardness and interracial bond strength of the VFS coatings was studied in detail. The experimental results show that there is a metallurgical bond area between the VFS WC-Co coatings and the steel substrate. The VFS coatings are characterized by the gradient hardness of the interface and the high bond strength to the steel substate, both of which are beneficial to the improvement of the wear resistance and corrosion resistance.

Tribological Behavior of Thermally Sprayed WC Coatings under Water Lubrication

Thermally sprayed coatings have been used in various fields of industry for enhancing surface characteristics of materials and extending their service life. The contact surface of some mechanical equipment such as the fine pulverization equipment which is used in the woody biomass production process is required to have wear resistance in the water environment. Thermally sprayed coatings would be a good candidate to improve surface wear resistance under water lubrication. The objective of this study was to evaluate the tribological performance of thermally sprayed coatings under water lubrication. Thermally sprayed coatings which were classified into WC, WB and Ni spraying of three categories were compared with water-lubricated sliding test at a sliding velocity of 0.02 m/s and mean pressure of p0 = 10 MPa with a ring-on-disk apparatus. Thermally sprayed coatings showed comparatively high friction coefficient and well wear resistance under water lubrication. WC contained coatings showed better wear resistance than WB and Ni coatings. Thermally sprayed coatings showed obviously different mechanical properties and tribological behaviors, and the effect of wettability and hardness on tribological characteristics was discussed under water lubrication. Friction coefficient increased as the surface contact angle of thermally sprayed coatings increased. The wear rate decreased as the surface hardness of thermally sprayed coatings increased. Wear resistance of thermally sprayed coatings was excellent under water lubrication. WC contained coatings showed lower wear rate than WB and Ni coatings. WC-14CoCr coating showed the lowest wear rate.

Microstructure and Properties Characterization of WC-Co-Cr Thermal Spray Coatings

WC-Co-Cr coatings are widely employed due to their improved wear resistance and mechanical properties, however, the properties and performance of these coatings are compromised by the processing parameters of each spraying technique. Therefore, this study is aimed to evaluate and determine the effect of the deposition parameters on the properties and microstructural characteristics of WC-Co-Cr coatings using a more economical thermal spray technique. In particular, the influence of flame spray parameters on the microstructure, crystal structure, hardness, and sliding wear resistance of WC- Co-Cr coatings was examined. Two parameters were considered: Type of flame (reducing, neutral and oxidizing), and the spray torch nozzle exit area. Results indicated that WC particles undergo considerable degree of decarburization and dissolution during spraying, showing substantial amounts of W2C, W, and Co3W3C, for all the considered conditions. However, the extent of phase transformation depended largely on the flame chemistry. The microstructure of the coatings was mainly affected by the spray nozzle. Regarding the sliding wear behavior, the coatings with uniform distribution of hard particles provided the best wear resistance. The decomposition of WC into W2C phase seems to have meaningless significance in the mass loss, nevertheless, the WC phase transformation to metallic tungsten and η-phase (Co3W3C) produce higher wear rates due to deficiency of carbide particles and embrittlement of the binder phase which induces cracking and delamination of the splats.

EFFECT OF DUCTILE-BRITYLE TRANSITION TEMPERATURE OF Al-Si COATING ON FATIGUE PROPERTIES OF Ni-BASE SUPERALLOYS

The effect of Al content on the ductile-brittle transition temperature of Al-Si coating and the effect of fracture behaviour.of the Al-Si coating on the fatigue properties of Ni-base superallovs have been investigated to propose the theoretical basis of search for an optimum of mechanical properties of the high temperature coating on Ni-base alloys.