Influence of Gas Pressure on the Mechanical and Tribological Properties of Cu-Al Coatings Deposited via Thermal Spray

Abstract

We report the results of the influence of the acetylene and oxygen gas pressure on the wear resistance of aluminum–bronze coatings deposited on naval brass substrate by means of the thermal (flame) deposition process. The coatings were characterized by means of scanning electronic microscopy (SEM), energy-dispersive X-ray spectrometry (EDS), X-ray diffraction (XRD), and X-ray fluorescence (XRF). The adhesion was determined with cross-hatching tests, and the mechanical response was assessed by measuring the nanohardness and by three-body and ball-on-disk abrasive wear tests. The results indicate that changes in the pressure and flow of the gas affect the morphology and the mechanical properties of the coatings, and these effects have consequences for the wear behavior of the coatings. Before the projection of the coatings, numerical simulations were carried out using Jets & Poudres software, where the collision speed of the particles was identified as the most significant factor that influences the mechanical properties and the performance of the coating. The gas pressure modified the hardness and the porosity level, which allowed improving the wear resistance.

Application of thermal spraying technology in concrete surface coating

“…The porosity of the coating can re ect its quality to a certain extent and directly re ect its protective performance. The distribution, morphology, and size of pores in the coating affect the mechanical, thermal insulation, corrosion, wear, and other properties of the coating [33] . There are many pores at the interface between the coating and the substrate, which weaken the bonding strength between the coating and substrate.…”

Effects of Cu-Ni-Ti Interlayer on Microstructure and Wear Resistance around Gas Tungsten Arc Cladding Copper Matrix Composite Coatings on Steel

“…The cladding materials included Cu-Al-Ti-Sn flux-cored wires for preparing copper matrix composite coatings, Cu-Ni-Ti fluxcored wires for preparing the interlayer, and S214 commercial aluminum-bronze wires for comparison with composite coatings in wear resistance. Al and Sn in the welding wires can strengthen the copper matrix, and Ti can react with C in situ to form TiC, which improves the wear resistance of the coatings [33][34][35]. All wires were 1.6 mm in diameter, and the chemical compositions are given in Table 2.…”