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.

Discharge and mass transfer characteristics of atmospheric pressure gas-solid two-phase gliding arc

In this work,a gas-solid two-phase gliding arc discharge(GS-GAD)reactor was built.Gliding arc was formed in the gap between the blade electrodes,and solid powder was deposited on the sieve plate positioned beneath the blade electrodes.A range of experimental parameters,including the inter-electrode spacing,gas flow rate,applied voltage,and the type of the powder,were systematically varied to elucidate the influence of solid powder matter on the dynamics of gliding arc discharge(GAD).The discharge images were captured by ICCD and digital camera to investigate the mass transfer characteristics of GS-GAD,and the electrical parameters,such as the effective values of voltage,current,and discharge power were record to reveal the discharge characteristics of GS-GAD.The results demonstrate that powder undergoes spontaneous movement towards the upper region of the gliding arc due to the influence of electric field force.Increasing the discharge voltage,decreasing relative dielectric constant of the powder and reducing the electrode-to-sieve-plate distance all contribute to a greater involvement of powder in the GAD process,subsequently resulting in an enhanced powder concentration within the GAD region.Additionally,powder located beneath the gliding arc experiences downward resistance caused by the opposing gas flow and arc.Excessive gas flow rate notably hampers the powder concentration within the discharge region,and the velocity of powder motion in the upper part of the GAD region is reduced.Under the condition of electrode-to-sieve-plate distance of 30 mm,gas flow rate of 1.5 L/min,and peak-to-peak voltage of 31 kV,the best combination of arc gliding and powder spark discharge phenomena can be achieved with the addition of Al_(2)O_(3) powder.

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.

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.

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.

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.

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.

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.

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.

Ni/Al Intermetallics Plasma Transferred Arc Processing

In-situ alloy development during surface processing allows for a limitless materials selection to protect components exposed to severe service conditions. In fact surface alloying offers the possibility to strengthen surface components with alloys that would not be possible to process otherwise. This work used Plasma transferred arc (PTA) hardfacing for surface alloying. Different amounts of aluminium powder, 5-25%, were added to a Ni based superalloy, from Hastealloy C family, in the atomized form. The mixture was homogeneized in a ball mill and PTA deposited on carbon steel substrate. The influence of different processing parameters on the final surface alloy was evaluated as current intensity and depositing velocity were varied. Coatings were characterized by optical and scanning electronic microscopy, X-ray diffraction and Vickers microhardness profiles, under a 500g load. Results showed that PTA hardfacing is an adequate surface alloying. For the conditions tested increasing hardness was obtained by solid solution for the lower amounts of Al added and due to the new intermetallic phases for the richer Al mixture.

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.

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.

Study on the formation of arc plasma on the resistive wall liquid metal current limiter

Due to its significant attributes,the liquid metal current limiter(LMCL)is considered a new strategy for limiting short-circuit current in the power grid.A resistive wall liquid metal current limiter(RWLMCL)is designed to advance the starting current-limiting time.Experiments are performed to investigate the dynamic behaviors of liquid metal,and the influence of different currents on the liquid metal self-shrinkage effect is compared and analyzed.Furthermore,the liquid metal self-shrinkage effect is mathematically modeled,and the reason for the formation of arc plasma is obtained by simulation.The laws of arc plasma formation and the current transfer in the cavity are revealed,and the motion mechanisms are explained by physical principles.The simulations are in accordance with the test data.It is demonstrated that the sudden change of the current density at both ends of the wall causes the liquid metal to shrink and depress under the electromagnetic force,and the current starts to transfer from the liquid metal path to the wall resistance path.The RWLMCL can effectively advance the starting current-limiting time.

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.

Analysis of the 3-D fluid velocity and temperature profile in keyhole plasma arc welding

Modeling and simulation of fluid flow and heat transfer in keyhole plasma arc welding is of great significance for optimizing the process parameters. In this study, a three-dimensional transient model is established to analyze numerically the heat transfer and fluid flow phenomena in keyhole plasma arc welding. VOF （volume of fluid） method is used to track the boundary of the keyhole. The dynamic developments of keyhole geometry, the fluid velocity field and temperature profiles are numerically simulated. And the changing Of the fluid velocity and pressure distribution on the keyhole wall in the forming process of the keyhole are analyzed.

THE INVESTIGATION ON PLASMA ARC TREATMENT OF CHROMIUM PLATED ALLOY STRUCTURE STEEL

The technology of plasma arc was used to modify the interface adhesion between c hromium coating and steel substrate. The interface microstructure was studied as a function of plasma arc processing parameters. Microstructure analysis was per formed by optical microscopy, scanning electron microscopy and electron probe. T he microhardness distribution along the depth of a cross-section of the chromium coating and the substrate was measured. The results show the energy density of transferred plasma arc is obviously higher than plasma non-transferred arc. The molten interface was obtained by plasma transferred arc. Interfaces between chro mium coating and steel substrate can be divided by plasma non-transferred arc in to three classes: non-molten, a little molten and molten. Good interface bonding was obtained by proper process parameters. The microhardness of chromium coatin g decreases with increasing energy density of plasma arc.

Effect of Injection Position on In-Flight Melting Behavior of Granular Alkali-Free Glass Raw Material in 12-Phase AC Arc Plasma

An innovative in-flight glass melting technology with a multi-phase AC arc plasma was developed to save energy and reduce emissions for the glass industry. The effect of the injection position on the in-flight melting behavior of granulated powders was investigated. Results show that the injection position has a strong effect on the melting behavior of alkali-free glass raw material. With the increase in injection distance, the vitrification, decomposition, and particle shrinkage of initial powders are improved. Longer injection distance causes much energy to transfer to particles due to a longer residence time of powder in the high temperature zone. The high vitrification and decomposition degrees indicate that the new in-flight melting technology with 12-phase AC arc can substantially reduce the melting and refining time for glass production.

特高压换流变用550kV防爆燃间隙油中电弧转移熄弧性能试验研究

特高压换流变充油量大,内部短路故障时会产生高能油中电弧,出现大的机械冲击力并产生大量高温高压油气,容易导致油箱结构撕裂和爆炸起火。为此提出在换流变网侧并联SF_6间隙,1 ms内导通并形成低阻气体电弧通道,快速转移熄灭高弧阻油中电弧的防爆燃技术方案,将传统故障清除时间缩短约80%。油中电弧转移受故障电弧特性的影响,但相关研究主要针对小电流的短油隙(<50 mm),长距离高能油中电弧特性仍未阐明。该文等效模拟换流变网侧内部放电工况,设计了试验回路、试验方式、油中燃弧模拟装置和高精度试验测控系统,成功开展6种方式油中电弧转移熄弧试验,获得了油中电弧特性和间隙转移熄弧能力。试验中设计油隙长度为250~650 mm,覆盖换流变500 kV和750 kV网侧最小油隙长度,参考换流站短路电流水平设计试验电流为20~50 kA、参考换流变保护出口时间设计间隙触发时延控制油中燃弧时间为2~10 ms。6次试验中间隙均能在1 ms内转移熄灭油中电弧。试验结果分析表明,换流变网侧最小油隙起始弧压不低于10 kV,随着油隙长度增加,单位长度弧压略微增加;在10~50 kA级短路电流下,油中弧压受电流幅值影响很小。该试验表明了间隙转移熄弧防爆燃的可行性和防爆燃间隙设计的有效性,为特高压换流变防爆燃提供了新的解决方案。

Plasma transferred arc forming technology for remanufacture

The plasma transferred arc （PTA） forming remanufacturing technology was introduced in this paper. This technology includes plasma surfacing, deposition and rapid forming technology. With self-developed plasma forming system, the thrust of engine cylinder body was remanufactured by PTA powder surfacing. In the concrete, the Nil5 alloy was deposited on the thrust face of the body in order to recover its dimension. In addition, the reman- ufacturing forming with Fe-based, Inconel 625 alloy was studied. The microstructure and hardness of the as-depos- ited materials were investigated.