Effects of process parameters and annealing on microstructure and properties of CoCrFeMnNi high-entropy alloy coating prepared by plasma cladding

Plasma cladding was used to prepare a CoCrFeMnNi high-entropy alloy(HEA)coating under different conditions.The process parameters were optimized using an orthogonal experiment design based on surface morphology quality characteristics,dilution rate,and hardness.The optimal process parameters were determined through range and variance analysis to be a cladding current of 70 A,a cladding speed of 7 cm·min^(-1),and a powder gas flow rate of 8 L·s^(-1).During the optimized experiments,both the cladded and annealed CoCrFeMnNi HEA coatings exhibit some pores,micro-voids,and a small amount of aggregation.However,the aggregation in the annealed coating is more dispersed than that in the cladded coating.The cladded CoCrFeMnNi HEA coating consists of simple FCC phases,while a new Cr-rich phase precipitates from the FCC matrix after annealing the coating at a temperature range of 550°C-950°C.After annealing at 850°C,the proportion of the FCC phase decreases compared to the cladded coating,and the number of large-angle grain boundaries is significantly reduced.However,the proportion of grains with sizes below 50μm increases from 61.7%to 74.3%.The micro-hardness and wear resistance of the cladded coating initially increases but then decreases with an increase in annealing temperature,indicating that appropriate annealing can significantly improve the mechanical properties of the CoCrFeMnNi HEA coatings by plasma cladding.The micro-hardness of the CoCrFeMnNi HEA coatings after annealing at 650°C increases to 274.82 HV_(0.2),while the friction coefficient decreases to below 0.595.

Microstructure and oxidation resistance of reactive plasma clad Cr_7C_3/γ-Fe ceramic composite coating

A new type oxidation resistance in situ Cr7 C3/γ-Fe ceramic composite coating was fabricated on hardened and tempered grade C steel by reactive plasma clad with Fe-Cr-C alloy powders. The oxidation resistance of the ceramic composite coating was investigated under the test condition of 900 ℃ and 50 hours. The results indicate that the coating has a rapidly solidified microstructure consisting of blocky primary Cr7 C3 and the inter-blocky Cr7 C3/γ-Fe eutectics and is metallurgically bonded to the hardened and tempered grade C steel substrate. The high temperature oxidation resistance of the coating is up to 1.9 times higher than that of grade C steel. The oxidation kinetics curve of the coating is conforming to the parabolic-rate law equation. The excellent oxidation resistance of the coating is mainly attributed to the continuous oxide films which consist of Cr203 and Fe203. The continuous oxide films can prevent the inner part of the coating from being further oxidized.

Microstructure and Corrosion Resistance of Cr_7C_3/γ-Fe Ceramal Composite Coating Fabricated by Plasma Cladding

A new type in situ Cr7C3/γ-Fe ceramal composite coating was fabricated on substrate of hardened and tempered grade C steel by plasma cladding with Fe-Cr-C alloy powders. The ceramal composite coating has a rapidly solidified microstructure consisting of primary Cr7C3/γ- and the Cr7C3/γ-Fe eutectics, and is metallurgically bonded to the degree C steel substrate. The corrosion resistances of the coating in water solutions of 0.5 mol/L H2SO4 and 3.5% NaCl were evaluated utilizing the electrochemical polarization corrosion-test method. Because of the inherent excellent corrosion-resisting properties of the constituting phase and the rapidly solidified homogeneous microstructure, the plasma clad ceramal composite coating exhibits excellent corrosion resistance in the water solutions of 0.5 mol/L H2SO4 and 3.5% NaCl.

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

A novel approach to produce an intermetallic composite coating was put forward.The microstructure,microhardness,and dry-sliding wear behavior of the composite coating were investigated using X-ray diffraction （XRD）,scanning electron microscopy （SEM）,energy dispersive spectrum （EDS） analysis,microhardness test,and ball-on-disc wear experiment.XRD results indicate that some new phases FeAl,Fe0.23Ni0.77Al,and Ni3Al exit in the composite coating with the Al2O3 addition.SEM results show that the coating is bonded with carbon steel metallurgically and exhibits typical rapid directional solidification structures.The Cr7C3 carbide and intermetallic compounds co-reinforced composite coating has a high average hardness and exhibits an excellent wear resistance under dry-sliding wear test compared with the Cr7C3 carbide-reinforced composite coating.The formation mechanism of the intermetallic compounds was also investigated.

Microstructure and wear resistance of Fe-Cr-Ti-C reactive plasma cladding coating

Fe-Cr-Ti-C composite powder was synthesized by precursor carbonization-composition process using the mixture of ferrotitanium, chromium, iron powder and precursor sucrose as raw material. And then the Fe-Cr-Ti-C coating was prepared by reactive plasma cladding method. Microstructure of the samples was observed by scanning electron microscope （SEM）, the phases were determined by X-ray diffraction （XRD）, and the wear resistance was evaluated under dry sliding wear test conditions at room temperature. Results indicate that the composite coating consists of primary austenite and dendritic eutectic austenite, chrysanthemum-shaped eutectic （Cr, Fe ） 7 C3 and TiC carbide. TiC presents the gradient distribution and different shapes in the coating, corresponding to equiaxial structure both in fusion zone and central zone, while it presents dendritic structure on the surface, respectively. The wear mass loss is insensitive to load for the coating while it increases rapidly for Q235 steel base metal in this test. The wear mass loss ofQ235 steel is 14 times as that of the composite coating under applied load of 40 kg.

Influence of process parameters on microstructure of reactive plasma cladding TiC-Fe-Cr coating

A certain amount of Ti was added to the plasma cladding Fe-Cr-C coating in the early stage in order to improve the quality and properties of the coating.Ti-Fe-Cr-C composite powder was prepared by precursor carbonization-composition process.In situ synthesized TiC-Fe-Cr coatings were fabricated on substrate of Q235 steel by plasma cladding process with the composite powder.Microstructures of the coatings with different process parameters,including cladding current,cladding speed,number of overlapping cladding layers,were analyzed by scanning electron microscope.The results show that the structure of the TiC-Fe-Cr coating is greatly affected by the cladding current,the cladding speed and the overlapping cladding process.In this test,when the cladding current of 300 A and the cladding process parameter of the cladding speed of 50 mm/min are clad with three layers,a well-formed and well-structured TiC-Fe-Cr coating can be obtained in this test.TiC-Fe-Cr coating has good wear resistance and good load characteristics under dry sliding wear test conditions.

Microstructure and corrosion resistance of high-chromium iron-base coating by plasma cladding

A new type of high-chromium iron-base coating was fabricated on substrate of hardened and tempered grade C steel by plasma cladding with Fe-Cr-C alloy powders. The coating has fine microstructure and is metallurgically bonded to the grade C steel substrate. The corrosion resistance of the coating in solutions of 0. 5 mol/L H2SO4 , 3.5 % NaCl and seawater was evaluated utilizing the electrochemical polarization corrosion-test method. Because of the inherent excellent corrosion- resisting properties of the constituting phase and the fine microstucture, the plasma clad coating exhibits excellent corrosion resistance in the water solutions of 0. 5 mol/L H2S04, 3.5% NaCl and seawater.

Study on Fe-based alloy Fe-Cr-Ti-C layers by reactive plasma cladding

Fe-based alloy Fe-Cr-Ti-C composite layers with and without titanium （ other powder ingredients are about the same） were fabricated on Q235 steel by plasma cladding process with high-energy plasma jet as heat source. Microstructure , phase composition and micro-hardness of the layers were investigated by optical microscope （OM）, X-ray diffraction （XRD）, electron probe microanalysis （ EPMA ） and micro-hardness tester. The results show that the grains of the cladding layers with Ti are much finer than that of the Fe-based cladding layer without Ti. Compared with the cladding layers without Ti, there are more shingle crystals in the cladding layers with Ti and the hard phase （ Cr, Fe ） 7 C3 of the eutectic in the layers increase gradually. However, as increasing titanium content in the alloy powder, the hard phase （Cr, Fe ） 7 C3 in eutectic structure of the cladding layer increases gradually, restraining （ Cr, Fe ）7 C3 carbide precipitation and decreasing the average and maximum hardness of the cladding layer.

Physical Characteristics of Plasma Cladding Fe-Cr-Nb-Si-Mo Alloy Cladding Layers on Different Substrates

A plasma cladding experiment was carried out to investigate the characteristics(surface hardness,microstructure,friction,wear properties from different substrates to the cladding layer and the bond strength)of plasma cladding Fe-Cr-Nb-Si-Mo alloy cladding layers on different substrates.In order to improve the abrasion resistance of the scraper middle trough,the plasma cladding technique was used to clad the alloy ceramic powder Ig7 on the surface of the middle trough NM450,WH60A,Hardox450,and Weartuf450 to create Fe/Cr/Nb/Mo/V cladding layer.Based on the experiment results,the microstructure,friction and wear properties of the four cladding layers were analyzed,and the bond strength between the cladding layer and the substrate was also tested.The experimental results show that the main phases of the four cladding layers are martensite and all kinds of metal carbides((Nb,Mo)C,VC,and Cr7C3).WH60A surface cladding layer has shown good friction and wear properties.

Plasma cladding of Stellite 6 powder on Ni76Cr19AlTi exhausting valve

Heavy duty engine valve head was prepared by Ni76Cr19AlTi alloy.It was coated by cobalt-base alloy on the surface topromote its wear-resistance.Hardness tester,metallograph,scanning microscopy,energy spectrum and X-ray diffraction were used toanalyze the mechanical properties,the microstructure of the welds and the coated layer of cobalt-base alloy.The results show that thegrains are obviously coasened in the side of Ni76Cr19AlTi alloy in the welds and it contains a typical dentritic structure in the sidecobalt-base alloy.It is found that micro-strain in weld is stronger than that in heat-effected-zone.Micro-strain in nickel-base alloy isstronger than that cobalt-base alloy.There are not obvious imperfects in the weld.Hardness in cobalt-base alloy is more than 390HVand the major carbides in cobalt-base alloy are Cr7C3 and W2C.

Optimization of shearer sliding boots by plasma cladding with Cr_4MnTi

Severe production conditions in coal mines cause damage and failure problems with the oriented sliding boots of the mechanical shearer. Wear has been an especially vexing problem. Plasma cladding methods were used to study optimized sliding boot design. By cladding the substrate steel the surface may be made of a material more resistant to wear. The iron based alloy Cr4MnTi was coated onto a modified 45 steel matrix material in these tests. The results show that the alloy cladding layer is high strength, has high hardness, and is highly resistant to wear. After hardening and tempering, 45 steel substrate has great tenacity so the combined structure meets the performance requirements for the construction of shearer sliding boots.

Microstructure of a Ni Matrix Composite Coating Reinforced by In-situ TiC Particles Using Plasma Cladding

Plasma cladding process was used to prepare the TiC/Ni composite coating on the mild steel substrates. The TiC particles were synthesized in-situ. Microstructure and properties of the coating were investigated by optical microscopy, X-Ray diffraction, SEM, TEM and microhardness tester. The results show that the interface between the coating and the substrate is metallurgically bonded. The coating was uniform and almost defect-free when [Ti+C] varied from 10% to 20% after ball milling. The microstructure of the coating is mainly composed of -Ni dendrite, interdendritic eutectic ( -Ni austenite, M23C6 and CrB) and TiC particles. Most of the TiC particles are spherical and a small fraction is blocky in size of l^2(im. The TiC particles are smaller at the bottom than near the top of the coating. The coating has a gradient microstructure and a highest hardness of lOOOHyO. 1.

Ultra wear resistant TiC-Fe coating prepared by high efficient and economic plasma cladding method

The key components of engineering machinery frequently failed due to working in the high load and high wear operating envir-onment.And the performance of the Fe-based alloy coatings typically employed need to be improved for fulfilling the service requirements.Herein,a TiC strengthened Fe-based alloy cladding layer,named TiC-Fe coating,was designed and prepared by plasma cladding technology.The frictional wear performance of coating under various loads was tested.The wear morphology of the coating was observed,and its wear mechanism was examined.The results indicated that the TiC-Fe coating was well formed and metallurgically bonded to the Q345C substrate.Its microstructure mainly consisted of Fe-Cr solid solution,α-Fe phase,(Fe,Cr)_(7)C_(3) phase and TiC phase.The coating exhibited an average microhardness of 980 HV0.2,which was about 5.4 times that of the Q345C substrate.The wear mass loss of the TiC-Fe coatings was much smaller than that of the Q345C substrate,which indicated that the wear resistance of the Q345C coating was superior to the substrate,and the wear mechanism of the coating was mainly attributed to the abrasive wear.

Influence of La2O3 addition on nano indentation hardness and residual stress of Stellite 6 coating prepared by plasma cladding

One of the problems limiting the application of Stellite 6 coating is the residual stress resulting in cracks in the coating easily. In order to reduce the residual stress and increase the nano-indentation hardness,La2 O3 was added to Stellite 6 coating in this study, and the influence on the microstructure, nano indentation hardness and residual stress of the coatings were investigated by scanning electron microscopy（SEM） with energy dispersive spectrum（EDS）, X-ray diffraction（XRD） and nano-indentation tester. Results indicate that the addition of La2 O3 leads to the phenomenon that the dendrite is partly transformed into the equiaxed grain, which results in the grain refinement. The nano-indentation hardness of coatings is improved, which is attributed to the fine-grain strengthening and dispersion strengthening effect of La2 O3. With the addition of La2 O3, the residual stress in coatings is decreased significantly. Especially, when the content of La2 O3 is 0.8 wt%, the nano indentation hardness increases by 1.31 times and residual stress decreases to 20 percent, compared with coating without La2 O3.

Microstructure evolution by plasma of WC/Fe-based coating cladding

The composite coatings were formed by plasma cladding Fe-based alloy（Fe-Cr-B-Si） added 10% , 30% and 50% （mass fraction） nickel-clad WC respectively on Q235 steel. The microstructure evolution and microhardness of the coatings were investigated. The WC particles were completely melted into the composites coating when 10% WC was added, however, when 30% or 50% WC was added, only part of them could be melted in the coatings. Two significantly different solidification microstructures were found. When WC content is 10% or 30%, the microstructure is mainly dendrites and inter- dendrite eutectics, while when the content of WC reaches 50% , it becomes remained WC particles, Fe3 W3 C carbide faceted dendrite and eutectics hypereutectic structure. The microhardness of these three coatings reaches 560- 600, 650 -810 and 920 - 1 100 HVo2 respectively, and is improved with the increasing of WC content.

Characteristics of Fe-based WC Composite Coatings Prepared by Double-pass Plasma Cladding Process

The Fe-based WC composite coatings were clad on Q235 steel by double-pass plasma cladding method,in which the WC-Co(WC covered with cobalt:78wt%WC,12wt%Co)doping was about 10wt%,20wt%and 40wt%,respectively.The microstructure and wear performance of the composite coatings were investigated by X-ray diffraction(XRD),scanning electron microscope(SEM),energy dispersive spectrometer(EDS)and ball-disc wear tests.The results show that the clad coatings contain mainly?-Fe,WC and carbides(Cr23C6,Fe3W3C-Fe4W2C)phases and the precipitation of carbides increases with the increase of WC-Co doping content.The WC-Co doping content has an obvious effect on the microstructure of the clad coatings.For the clad coatings with low WC-Co doping,the microstructure gradually transforms from planar crystal at the interface of substrate/coating to cell/dendritic crystal at the middle and the upper portion of the coatings.But there are a number of fishbone-like structure at the middle and the upper portion of clad coating with 40wt%WC-Co doping.The microstructure at the top is smaller than that at the bottom for all the coatings.The maximum of hardness of the clad coatings is 72.3HRC which is about 6.9 as much as the hardness of Q235 steel substrate.The composite coatings have good wear resistance due to the reinforcement of carbide particles and the strong bonding between carbide particles and ferroalloy.The suitable increase of WC-Co doping content can improve the wear resistance of the composite coatings.

Pulsed plasma arc cladding

A prototype of Pulsed Plasma Arc Cladding system was developed, in which single power source supplies both transferred plasma arc (TPA) and non-transferred plasma arc (N-TPA). Both plasmas work in turn in a high frequency controlled by an IGBT connecting nozzle and workpiece. The working frequency of IGBT ranges from 50 ～ 7 000 Hz, in which the plasmas can work in turn smoothly. Higher than 500 Hz of working frequency is suggested for promotion of cladding quality and protection of IGBT. Drag phenomenon of TPA intensifies as the frequency goes up, which tends to increase the current proportion of TPA and suppress N-TPA. The occupation ratio of IGBT can be regulated from 5% ～ 95%, which balances the power supplies of both plasmas. An occupation ratio higher than 50% gives adequate proportion of arc current for N-TPA to preheat powder.

热处理对等离子熔覆Fe-Mo-Cr-Ni-B合金覆层组织及耐磨性能的影响

采用等离子熔覆技术在H13合金钢表面熔覆Fe-Mo-Cr-Ni-B合金,利用光学显微镜(OM)、扫描电子显微镜(SEM)配合能谱仪(EDS)、X射线衍射仪(XRD)、显微硬度计以及多功能摩擦磨损试验机,对热处理前后熔覆层的组织结构、硬度和耐磨性进行分析。结果表明,Fe-Mo-Cr-Ni-B合金覆层主要由α-Fe、Mo_(2)FeB_(2)、(Mo,Fe,Cr)_(3)B_(2)和Fe_(23)(B,C)_(6)相组成;熔覆层磨损以Mo_(2)FeB_(2)硬质相的脆性剥落为主;在1000℃温度热处理后,熔覆层平均硬度达到1061HV_(0.5),相比于焊态提高了28.3%,耐磨性相比于焊态提升了42.0%。合金覆层硬度提升和耐磨性的改善可以归因于高温热处理导致的碳化物共晶组织消失、Mo_(2)FeB_(2)硬质相增多以及黏结相强度增加。

等离子弧熔覆Fe-C-B-V系耐磨堆焊层的组织及性能研究

以硼铁、高碳铬铁、钒铁为原料,采用等离子弧熔覆技术在Q345钢表面堆焊Fe-C-B-V系铁基合金。使用金相显微镜、扫描电镜和X射线衍射仪等研究了堆焊层的显微组织;分别使用维氏硬度计和冲击试验机测量堆焊层的显微硬度和冲击韧性。结果表明,堆焊层显微组织主要由马氏体、网格状Fe_(3)(C,B)和Fe_(2)B、弥散分布的碳化物及硼化物等(如VB_(2)、VC、Cr_(2)B)硬质相构成;堆焊层的平均硬度高达904.58 HV10、冲击功为68.5 J。堆焊过程中形成的硼化物、碳化物作为硬质相提高了堆焊层的硬度和耐磨性,形成的碳化钒使组织从鱼骨状变成网格状,细化了晶粒,提高了堆焊层的冲击韧性。

熔覆电流对高钼高钒铁基硬质涂层组织结构与性能的影响

刃板的磨损失效往往导致整个挖斗报废,为了提高其耐磨性能,采用等离子熔覆技术在刃板材料Q345B表面制备高钼高钒铁基耐磨涂层,研究熔覆电流(120、140、160 A)对涂层组织结构的影响,考察涂层的显微硬度、摩擦磨损与耐冲击性能。结果表明,电流大小对涂层的组织结构与界面状态影响较大,涂层组织主要由马氏体基体、弥散分布的细小球形碳化钒(VC)、多边形块状硼化钼(Mo_(2)B)和层片状复合硼碳化物(M_(2)(B,C))组成。120 A下制备的涂层与基材界面处存在局部未熔合区,增大电流导致涂层中VC的尺寸和分布间距变大,Mo_(2)B消失,M_(2)(B,C)增多且尺寸增大。涂层的平均显微硬度约为920 HV0.1,是耐磨钢NM400的2倍多,同等条件下的磨损失重仅为NM400的1/20,表现出优异的耐磨性能。带基材的涂层具有良好的耐冲击性能,且平行熔覆纹路的耐冲击性能优于垂直熔覆纹路的。