WC–W2C composites of three different compositions have been synthesized from mixture of WC + W (0, 5 and 16 wt% W) by thermal arc plasma melt-cast technique. Various grown phases observed in the composites consisting of major phases of WC and W2C and minor phases of unbound C (graphite) and tungsten (W) were confirmed by X-ray diffraction, selected area electron diffraction, X-ray photoelectron spectroscopy and Fourier transform infrared studies. Transmission electron microscopy and field emission scanning electron microscopy show polycrystalline nature of composites. Energy dispersive spectroscopy (of X-ray) infers the absence of any impurity in the composite. Almost porous free nature of composites were observed from X-ray micro computed tomography and BET analysis studies. WC–W2C composite (16 wt% W) shows 25% and 21% higher micro hardness (2535 VHN) and Young’s modulus (625 GPa) values than that of pure melt cast WC sample.
Phosphating is a widely used metal pre-treatment process due to its ability to improvise pitting corrosion resistance, wear-resistance, and adherence properties. In the present investigation, we report the manufacturing of spray grade powder of Fe-P metal ingot by mechanical hammering, milling and sieving process. The Fe-P powder and its blending with reduced graphene oxide (rGO) (2 and 4 vol %) were successfully coated over mild steel by thermal plasma spray method for the first time. Successful retention of rGO was observed even after thermal plasma spraying of Fe-P/rGO (2 vol % and 4 vol %), which was challenging and yet to be reported. The morphological investigation of the top-coat layer and cross-section was analysed using a field emission scanning electron microscope (FESEM). The presence of G, D and 2D bands at 1580 cm−1, 1350 cm−1, and 2700 cm−1, respectively in the Raman spectra were the straight forward demonstration of the retention of rGO. Hardness and air-jet erosion tests were performed to evaluate mechanical properties in view of exploring commercial applications of such coatings. We found that Fe-P-rGO composite coatings exhibited improved hardness, erosion, and corrosion resistance properties with increasing reduced graphene oxide content.
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