Milling of Complex Surfaces of EN 10060 Steel after HVOF Sprayed NiCrBSi Coatings

Abstract

The high-velocity oxy-fuel spraying process was used to investigate and improve the surface properties of a workpiece. The research was focused on the spherical surface of a workpiece made of high-strength steel, a ball and socket assembly. After spraying with a nickel alloy, the surface was machined by milling. The coating was carried out as a process in which a very thin layer of coating of the required thickness and the required specific properties, i.e., high Vickers hardness, adhesion to the surface, wear resistance and other important characteristics, which must be respected in other machining methods, was applied to the already finished, heat-prepared metal substrate. This article deals with the milling of complex surfaces of steel substrate EN 10060 after spraying with NiCrBSi alloy. After spraying, a total of 15 milling experiments were performed in order to determine precisely the optimal cutting parameters of milling and surface adhesion, based on newly acquired prediction relations. The main presented results are new relations for the determination of optimal technological milling conditions based on the identification of adhesive sections using derived equations. The new relations were verified and also compared with the current literature in the field.

Thermodynamics and Mechanics of Thermal Spraying of Steel EN 10060 Substrate with NiCrBSi Alloy after Milling

“…Both Equations are derived by the authors of the article, they are experimentally and statistically verified and have been published for many years, e.g., [ 28 , 29 , 30 ], etc., or are also the content of patents [ 31 , 32 ]. They are very important in our application solutions because they simulate laboratory tensile and compressive tests for diagrams σ-ε , or σ- Δ h with relatively precise localization of the position and the value of the yield strength Re , and thus also the position of the neutral deformation plane h 0 and other stress-strain parameters of the materials.…”

“…The genesis of the research is based on previous publications on cobalt and nickel alloys (Stellite 1,2, Stellite 6 as the Co-Cr-W), which were finally machined by turning [ 28 , 29 , 30 ]. In this research, we dealt with the interaction of individual parameters.…”