Sensitivity analysis and optimisation of HVOF process inputs to reduce porosity and maximise hardness of WC-10Co-4Cr coatings

Prasad, Resmi V; Rajesh, R.; Thirumalaikumarasamy, D.; Vignesh, S.; Sreesabari, S

doi:10.1007/s12046-021-01667-4

Cited by 10 publications

(5 citation statements)

References 25 publications

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“…The coating properties are greatly influenced by porosity [50]- [52]. The hardness of the coating layer increases as the percentage of porosity and unmelted material decreases.…”

Section: Resultsmentioning

confidence: 99%

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Influence of Post-Heat Treatment on the Characteristics of FeCrBMnSi Coating on Stainless Steel 304 Substrate Prepared by Twin Wire Arc Spray (TWAS) Method at Various Stand-off Distance

2024

jjmie

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Twin wire arc spray (TWAS) is a type of thermal spray coating technology that has been extensively researched to improve the service life and overcome wear, cavitation and corrosion in pump impellers. This study aims to investigate the effect of post-heat treatment on the properties of FeCrBMnSi coatings fabricated by the Twin Wire Arc Spray (TWAS) method on 304 stainless steel substrates with varying stand-off distances. NiAl and FeCrBMnSi were employed as bond coats and top coats in this study. The substrate material was sandblasted before the coating process to achieve a surface roughness of 75-100 µm. The TAFA 9000 Electrical Wire-Arc Spraying machine's voltage (V), current (A), and compressed air pressure (Bar) were set to 28.4; 150; and 5, respectively. The coating operation was performed at 100, 200, and 300 mm stand-off distances. The specimens were then post-heated for 3 hours at 500°C and 700°C in a Thermolyne F6010 Furnace Chamber. The quality of the coating produced in this study was evaluated using thickness, hardness, wear, bond strength, micrography, and SEM (Scanning Electron Microscope) testing. According to the findings of this study, specimens with a stand-off distance of 100 mm and a post-heat treatment temperature of 700 o C produce the best coating qualities when compared to other specimens. This specimen resulted in a percentage of porosity and unmelted material, thickness, hardness, adhesive strength, and total wear rate of 7.1%, 5.53 x 10 -1 mm, 1460 HV, 24.86 MPa, and 3.8 x10 -4 mm 3 /s, respectively.

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“…The coating properties are greatly influenced by porosity [50]- [52]. The hardness of the coating layer increases as the percentage of porosity and unmelted material decreases.…”

Section: Resultsmentioning

confidence: 99%

“…Porosity causes inadequate coating cohesion and reduces the ability to endure indentation loads, resulting in a decrease in hardness. Furthermore, porosity in the coating can result in rising corrosion rates and wear [50]- [52]. The porosity of a coating is inversely related to its hardness.…”

Section: Resultsmentioning

confidence: 99%

Influence of Post-Heat Treatment on the Characteristics of FeCrBMnSi Coating on Stainless Steel 304 Substrate Prepared by Twin Wire Arc Spray (TWAS) Method at Various Stand-off Distance

2024

jjmie

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“…The distance between indentations was kept three times longer than the indentation diagonal to prevent the effects of the stress field of nearby indentations. Published literature and laboratory investigations clearly state that factors such as fuel and gas flow rate, powder particle feed rate and spray distance have a huge impact on the act of HVOF coatings [14][15][16][17][18][19]. Thus, it is key to regulate the optimum conditions of the above factors to achieve low levels of porosity and maximum hardness.…”

Section: Experimental Procedures and Methodsmentioning

confidence: 99%

Optimisation of HVOF Spray Process Parameters to Achieve Minimum Porosity and Maximum Hardness in WC-10Ni-5Cr Coatings

et al. 2022

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High-velocity oxy-fuel (HVOF) spray coating plays a major role in many surface treatment methods, which tend to improve erosion and corrosion resistance properties. HVOF is well known for its dense and high-quality coating ability. This is due to the less in-flight exposure time, which tends to have less oxide content because of its high-velocity properties. Among the number of process parameters, porosity and hardness are predominant factors while considering wear rate and corrosion behaviour analysis. The current study aims to optimise HVOF process parameters to obtain low levels of porosity and high hardness values in the WC-10Ni-5Cr coating sprayed on 35 Mo Cr steel. The flow rates of oxygen, LPG, coating powder feed rate and spray distance are selected in this study as these have a superior influence on the final condition of the coating. Statistical tools such as the design of experiments (DoE), analysis of variants and response surface methodology (RSM) were used to achieve the desired results. As per the result analysis, the oxygen flow rate has a higher effect on the porosity value and microhardness value of the coating.

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“…It is important to choose the right spray process and parameters, such as fuel gas type, particle velocity, and spray distance [21]. By using thermal spray (TS) technology, the thickness of the coating on the treated substrate can be increased by increasing the number of passes during the spraying process [22], and porosity decreases with higher particle temperature [23].…”

Section: Introductionmentioning

confidence: 99%

Optimizing the Thermal Spray Parameters for Producing High-Performance Mo/ZrB2 Metal Matrix Composites Using the Taguchi Method

Mihoob,

Albarody,

Ahmad

et al. 2023

Coatings

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The process of Thermal spray is effective for creating a metal matrix composite (MMC) by embedding zirconium diboride reinforcement into a molybdenum matrix. Both materials Mo and ZrB2 have different characteristics, but they have good thermal shock resistance, maintain strength at elevated temperatures, and stability in extreme environments. The study focused on creating MoZrB2 composites using a thermal spray coating technique, varying the parameters of spraying distance, number of passes, and gas pressure, and testing the resulting castings to evaluate their hardness and Young’s Modulus. The primary objective of the research was to use the Taguchi technique for identifying the optimal parameters for generating the highest Young’s Modulus and hardness for the castings. The Taguchi method integrates experimental and analytical principles to identify the most significant parameter affecting the response, which can significantly enhance overall performance. The study found that the optimal parameters were a spraying distance of 20 cm, gas pressure of 6 bar, and the number of passes of 18. The Taguchi method accurately predicted the parameters that produced the highest properties for the composite coatings, which demonstrated good surface formation without hot cracks and fewer pores, with well-formed metallurgical bonding between the coating and the substrate.

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Sensitivity analysis and optimisation of HVOF process inputs to reduce porosity and maximise hardness of WC-10Co-4Cr coatings

Cited by 10 publications

References 25 publications

Influence of Post-Heat Treatment on the Characteristics of FeCrBMnSi Coating on Stainless Steel 304 Substrate Prepared by Twin Wire Arc Spray (TWAS) Method at Various Stand-off Distance

Influence of Post-Heat Treatment on the Characteristics of FeCrBMnSi Coating on Stainless Steel 304 Substrate Prepared by Twin Wire Arc Spray (TWAS) Method at Various Stand-off Distance

Optimisation of HVOF Spray Process Parameters to Achieve Minimum Porosity and Maximum Hardness in WC-10Ni-5Cr Coatings

Optimizing the Thermal Spray Parameters for Producing High-Performance Mo/ZrB2 Metal Matrix Composites Using the Taguchi Method

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