Development of Al₂O₃-based hybrid ceramic matrix composite coating to mitigate the erosive wear of advanced steel

Abstract

Steels are susceptible to surface- and subsurface-related degradations (e.g. corrosion and wear) depending upon the working environment; however, desired properties can resolve these issues. The authors have selected the high-velocity oxygen-fuel process to develop alumina-based composite coatings on ASME SA 387 GR22 CL2 steel. The coating material chosen comprises ceria and hexagonal boron nitride as the reinforcements. The metallurgical characteristics of coatings are recorded using X-ray diffraction and scanning electron microscopy. Mechanical properties are mapped using a nano-indenter; and an air jet erosion test rig is used to evaluate erosion wear response. Improvements in the mechanical properties and erosive wear resistance of the hybrid coating are attributed to microstructural changes and the generation of new phases. The values of [Formula: see text], [Formula: see text], and [Formula: see text] are used to develop the mechanistic understanding of coatings’ erosion behavior. Splat cracking and splat detachment are the observed erosion wear mechanisms.

Wear behavior of bare and coated 18Cr8Ni turbine steel exposed to sediment erosion: A comparative analysis

“…The addition of the alumina into the alloy coating (Co-NiCrAlY) increased its overall hardness leading to the strengthening of coating structure by restricting the material's flow by the erodent impact. Less deformation and wear of such composite coating structures have also been reported in earlier study [8]. In Co-NiCrAlY, the existence of Ni-Al leads to the development of intermetallic phases that enhance the coating's capacity to adhere to the substrate material [13].…”

“…HVOF is a thermal spray coating technique in which material is sprayed onto a surface to form a protective layer. HVOF produces coatings with a high density that are harder and more wear-resistant than other thermal spray techniques [8]. HVOF coatings provide a smooth finish and strong adhesion between the coating and the substrate, making them less susceptible to peeling, flaking, and chipping [8].…”

“…HVOF produces coatings with a high density that are harder and more wear-resistant than other thermal spray techniques [8]. HVOF coatings provide a smooth finish and strong adhesion between the coating and the substrate, making them less susceptible to peeling, flaking, and chipping [8]. Singh et al [9] reported in their study that the uncoated (bare turbine steel) and the coated turbine steel show different behaviour under the impact of sediment erosion at different angles and velocities.…”

High temperature tribological and electrochemical behavior of heat-treated Al2O3-base hybrid coating sprayed by HVOF thermal spray technique

“…Gupta and Kumar studied the various compositions of Al 2 O 3 -based composite coating. The coating with 3%-6% reinforcement showed enhanced mechanical and erosion characteristics [29]. The MoS 2 , graphite and fumed silica in w/w % of 10%, 5% and 5%, respectively were used as reinforcement to enrich the base coating material.…”