Investigation of Microwave Processing Parameters on Development of Ni-40Cr3C2 Composite Clad and Their Characterization

Proceedings of the Institution of Mechanical Engineers, Part L:

et al. 2020

Self Cite

Cavitation erosion is the primary cause of material failure of the hydroelectric power plant components. The rapid development in the advanced surface engineering techniques has provided an effective treatment solution for cavitation erosion. One such novel method is microwave cladding. Hence, the Ni–40Cr3C2 composite clad was deposited on austenitic stainless steel (SS-316) using a microwave cladding process in the present study. The processing was carried out in a domestic microwave oven of 2.45 GHz frequency and 900 W power. The developed clad was thoroughly characterized for the metallurgical and mechanical properties related to its behavior as a successful cavitation erosion resistance material, like microstructure, crystal structure, porosity, microhardness, flexural strength, and fracture toughness. The results showed that the stripe-type and agglomerated carbides were present in the Ni–40Cr3C2 clad. The developed composite clad consists of various carbides (SiC, Ni3C, Cr3Ni2SiC, Cr7C3, and NiC) and intermetallic phases (Ni3Fe, Ni2Si, and Cr3Si). Microhardness, flexural strength, and fracture toughness of the microwave-processed clad were observed to be 605 ± 80 HV0.3, 813.23 ± 16.2 MPa, and 7.44 ± 0.2 MPa√m, respectively. The microwave-processed composite clad performance in terms of cavitation erosion resistance was determined using the ultrasonic apparatus (ASTM-G32-17). The cavitation experiments were carried out according to Taguchi L9 orthogonal array, taking into account three parameters: standoff distance, amplitude, and immersion depth. The developed composite clad exhibited significant resistance (mass loss 7.6 times lesser as compared to SS-316) to cavitation erosion. ANOVA results showed the standoff distance as the most important factor followed by amplitude and immersion depth. Least cavitation resistance was observed at a smaller standoff distance, higher amplitude, and lower immersion depth. Linear regression equations were obtained to establish the correlation between parameters and cumulative mass loss. The microwave clad specimens tested at optimized test parameters were damaged in the form of fractured intermetallic, extruded lips, pits, and craters.

Section: Resultsmentioning

confidence: 99%

“…The schematic and the actual setup of the cladding process with MHH is shown in Figure 3, whereas the optimized processing conditions for microwave-processed Ni–40Cr 3 C 2 composite clad is summarized in Table 4. The complete mechanism 59 and optimization procedure 60 of the microwave cladding process is reported elsewhere.…”

Section: Materials and Methodologymentioning

confidence: 99%

Cavitation erosion behavior of microwave-processed Ni–40Cr₃C₂ composite clads: A parametric investigation using ultrasonic apparatus

Mago

Bansal

Proceedings of the Institution of Mechanical Engineers, Part L:

et al. 2020

Self Cite

“…27 Cr 3 C 2 -based ceramic was used as a reinforced material owing to its good wearresistance property. 28…”

Section: Materials Detailmentioning

confidence: 99%

“…27 Cr 3 C 2 -based ceramic was used as a reinforced material owing to its good wear-resistance property. 28 Energy dispersive spectroscopy (EDS) was used to analyze the elemental compositions of raw powders and SS304 substrate, which are tabulated in Table1. The mean particle sizes of Ni-based and Cr 3 C 2 -based ceramic powders were 37± 5 μm and 30 ± 6 μm, respectively.…”

Section: Experimentationmentioning

confidence: 99%

Novel investigation on tribological behavior of microwave synthesized functionally graded claddings

Kaushal

Proceedings of the Institution of Mechanical Engineers, Part C:

Bhowmick

2021

Self Cite

In this study, functional performance of Ni/Cr3C2 functionally graded claddings (FGCs) was investigated under dry sliding wear environment. The Ni/Cr3C2-based FGCs were produced by varying Cr3C2 fraction (Ni-XCr3C2) (X=10%–30% by weight) using microwave irradiation. The FGC layers were composed of cellular-structure with reinforced particles dispersed randomly inside Ni-based matrix. Variation of Cr3C2 particles inside Ni matrix exhibited significant impact on micro-structural and mechanical properties. The microhardness profile of the FGC layers showed an increase in hardness value with an increase in the amount of reinforced Cr3C2 particles. FGC top layers showed the maximum value of micro-hardness of 555 ± 34 HV. Functional performance of microwave processed FGCs was studied through the pin-on-disk tribometer under varying sliding velocity and sliding distances. For comprehension study, wear study was also carried out on microwave processed single layer clads with compositions corresponding to FGC layers. The FGC sample showed better wear resistance than all single clad layers and substrate material. The FGC sample exhibited 1.6 times less wear rate than the Ni-based + 30% Cr3C2 single layer clad. The worn-out surfaces of FGC and single-layer-clads showed presence of multiples cracks and grooves, which resulted in their weight loss during dry sliding contact. Material debonding and the formation of craters and cracks are the main phenomena responsible for the wear loss in the FGC surface.

“…Metal-matrix composite claddings are commonly used in demanding engineering applications owing to their exceptional wear resistance attributes. 3,4 Further, wear performance of any surface can be enhanced by the addition of carbides/oxides hard particles (WC, SiC, Cr 3 C 2 , etc.). [5][6][7] These hard particles are primarily mixed with metallic binders to form metal-matrix composite coating/cladding, which is associated with excellent mechanical and wear resistance characteristics.…”

Section: Introductionmentioning

confidence: 99%

Wear behavior of microwave-processed Ni-WC8Co-based functionally graded materials

Kaushal¹,

Proceedings of the Institution of Mechanical Engineers, Part L:

Bhowmick

2021

Self Cite

Functionally graded materials are inhomogeneous materials with the gradual change in properties with position. In this research work, functionally graded clad layers of Ni-WC8Co-based materials with varying compositions of WC8Co from 0 to 30 wt% were processed using a cost-effective and energy-efficient microwave hybrid heating technique. Single-layer clads of compositions corresponding to different functionally graded clad layers were also developed through microwave heating for comparing different properties. The processed functionally graded clads were characterized through microstructural analysis (scanning electron microscopy/energy-dispersive X-ray spectroscopy) and Vicker’s microhardness quantification. Microstructure results showed the functionally graded clad of approximately 2 mm thickness was free from any visible pores and interfacial cracks. Microwave heating resulted in the formation of hard phases in the functionally graded clad layers, and these layers exhibited significantly higher microhardness values. Further, the tribological performance of developed functionally graded clad was examined under dry sliding conditions using pin-on-disk-type tribometer. The influence of varying sliding velocities and sliding distances on the wear characteristics of microwave-processed functionally graded clads were investigated. It was observed that microwave-processed functionally graded clad exhibited approximately 95%, and 29% higher wear resistance than the SS-304 substrate and Ni + 30%WC8Co-based single-layer clad respectively owing to its better mechanical properties.