The surface preparation of shiny stainless steels is a must for applying esthetic paints, effective functional plasma spray coating, laser cladding, welding, etc., applications. The current work aims for effective surface roughening and erosion MRR of SS 304 work surface using SiC abrasive jet erosion and optimization of the process parameters. The response surface approach is used to design and conduct the studies using the Box–Behnken design method. The surface topography of the eroded surfaces is examined by a 2D profilometer, 3D profilometer, and scanning electron microscope (SEM). The abrasive grit size and working gas pressure greatly affect the surface roughness of SS 304 samples. The influence of the process parameters on the variation of these topographical features is analyzed and confirmed. The working jet pressure is seen to significantly impact erosion MRR. The lower working gas pressure shows a typical influence on Ra (surface preparation) and as pressure increases, erosion MRR rises, and the surface preparation mode shifts to the erosion metal removal/cutting zone. The quality of SS 304 surface prepared from SiC abrasive jet impact is characterized by 3D profilometry.
A thermally sprayed coating consists of multiple layers of different materials, that is, topcoat, bondcoat, and substrate. These three layers form two different junctions, namely, topcoat-bondcoat, and bondcoat-substrate. The residual stress state in two different materials in the interfaces was investigated using a systematic X-ray diffraction-based procedure consisting of phase and stress analysis. A transfer of residual stress from one material to the other was found to take place at the interfaces. The residual stress state of the topcoat influenced the stress field of the bondcoat, whereas the residual stress of substrate was affected by the stress state of the bondcoat at the interfaces. It was also perceived that the residual stress field along the depth of a multilayer coating system can be measured using a single X-ray target with a proper investigation procedure, eliminating the need of using different X-ray sources for different materials. It was found that the residual stress from one material transfers to another, and in the process, clamping of one surface by the other takes place at multiple locations throughout the surface. This is how mechanical interlocking between two layers takes place. Thus, the result can provide a basic understanding on the micro-mechanism of coating adhesion.
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