Engine blocks of modern passenger car engines are generally made of light metal alloys, mostly hypoeutectic AlSi-alloys. Due to their low hardness, these alloys do not meet the tribological requirements of the system cylinder running surface-piston rings-lubricating oil. In order to provide a suitable cylinder running surface, nowadays cylinder liners made of gray cast iron are pressed in or cast into the engine block. A newer approach is to apply thermal spray coatings onto the cylinder bore walls. Due to the geometric conditions, the coatings are applied with specifically designed internal diameter thermal spray systems. With these processes a broad variety of feedstock can be applied, whereas mostly lowalloyed carbon steel feedstock is being used for this application. In the context of this work, an iron-based wire feedstock has been developed, which leads to a nanocrystalline coating. The application of this material was carried out with the Plasma Transferred Wire Arc system. AlMgSi0.5 liners were used as substrates. The coating microstructure and the properties of the coatings were analyzed.
Reactive air brazing (RAB) is an emerging technology for the production of ceramic-to-ceramic and ceramic-to-metal joints. In this study, RAB was investigated with respect to the potential applications for solid oxide fuel cells (SOFCs) as one example of use. It was found that alumina could be well brazed by RAB with AgCu and AgCuTi brazes. Both braze composition and brazing temperature influenced significantly the wetting behavior and their mechanism of wetting. AgCu and AgCuTi braze alloys could also be used to produce brazed joints with the SOFC materials ceramic yttria stabilized zirconia and steel X1CrTiLa22. However, CuO reacts with the steel, forming a brittle oxide layer on the steel surface, which is undesirable for SOFC applications. The first trials with Ag0.5Al showed a promising solution.
This paper presents the influence of the grinding-burnishing on surface integrity and corrosion performance of the laser-cladded AISI 431 alloys. As-cladded specimens were first ground followed by plasticity ball burnishing. To evaluate surface alteration and performance enhancement, six major properties were measured and analysed in terms of surface roughness, porosity, microhardness, wear, and impact and corrosion resistance. Results showed that grinding-burnishing significantly improved the surface finish by lowering Ra and Rz by up to 29% and 41%, respectively, compared to grinding, while surface porosity was found to decrease by 18%. Maximum surface microhardness increased by 32% when grinding-burnishing, with a modified depth of up to 250 μm, while wear resistance increased by up to 38%. Because of hardness improvement, the grinding-burnishing increased the impact resistance by lowering the maximum indent depth by 29%. The corrosion resistance improved by increasing positive corrosion potential from − 0.31 V (grinding) to − 0.21 V (grinding-burnishing) and lowering corrosion current density from 1.18 × 10−3 A.cm−2 (for grinding) to 2.1 × 10−5 A.cm−2 (grinding-burnishing). Burnishing further induced grain modification in terms of grain deformation and flattening within microstructure, but no significant grain refinement was observed. XRD results however showed lattice deformation indicating potential compressive residual stress generated by burnishing. Overall, it is imperative to say that the combined grinding-burnishing can be a viable surface modification technique to extend functional service life of the laser-cladded components.
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