Mechanical and Tribological Properties of HVOF-Sprayed (Cr<Subscript>3</Subscript>C<Subscript>2</Subscript>-NiCr+Ni) Composite Coating on Ductile Cast Iron

The aim of the investigations was to compare the microstructure, mechanical, and wear properties of Cr₃C₂-NiCr+Ni and Cr₃C₂-NiCr coatings deposited by HVOF technique (the high-velocity oxygen fuel spray process) on ductile cast iron. The effect of nickel particles added to the chromium carbide coating on mechanical and wear behavior in the system of Cr ₃ C ₂ -NiCr+Ni/ductile cast iron was analyzed in order to improve the lifetime of coated materials. The structure with particular emphasis of characteristic of the interface in the system of composite coating (Cr ₃ C ₂ -NiCr+Ni)/ductile cast iron was studied using the optical, scanning, and transmission electron microscopes, as well as the analysis of chemical and phase composition in microareas. Experimental results show that HVOF-sprayed Cr₃C₂-NiCr+Ni composite coating exhibits low porosity, high hardness, dense structure with large, partially molten Ni particles and very fine Cr₃C₂ and Cr₇C₃ particles embedded in NiCr alloy matrix, coming to the size of nanocrystalline. The results were discussed in reference to examination of bending strength considering cracking and delamination in the system of composite coating (Cr ₃ C ₂ -NiCr+Ni)/ductile cast iron as well as hardness and wear resistance of the coating. The composite structure of the coating provides the relatively good plasticity of the coating, which in turn has a positive effect on the adhesion of coating to the substrate and cohesion of the composite coating (Cr₃C₂-NiCr+Ni) in wear conditions.     

The High-Temperature Wear and Oxidation Behavior of CrC-Based HVOF Coatings

Three commercially available chromium carbide-based powders with different kinds of matrix (Cr₃C₂-25%NiCr; Cr₃C₂-25%CoNiCrAlY and Cr₃C₂-50%NiCrMoNb) were deposited by an HVOF JP-5000 spraying gun, evaluated and compared. The influence of heat treatment on the microstructure and properties, as well as the oxidation resistance in a hot steam environment (p = 24 MPa; T = 609 °C), was evaluated by SEM and XRD with respect to their potential application in the steam power industry. The sliding wear resistance measured at room and elevated (T = 600 °C) temperatures according to ASTM G-133. For all three kinds of chromium carbide-based coatings, the precipitation of secondary carbides from the supersaturated matrix was observed during the heat treatment. For Cr₃C₂-25%NiCr coating annealed in hot steam environment as well as for Cr₃C₂-25%CoNiCrAlY coating in both environments, the inner carbide oxidation was recorded. The sliding wear resistance was found equal at room temperature, regardless of the matrix composition and content, while at elevated temperatures, the higher wear was measured, varying in dependence on the matrix composition and content. The chromium carbide-based coating with modified matrix composition Cr₃C₂-50%NiCrMoNb is suitable to replace the Cr₃C₂-25%NiCr coating in a hot steam environment to eliminate the risk of failure caused by inner carbide oxidation.     

Microstructure and Properties of FeCrB Alloy Coatings Prepared by Wire-Arc Spraying

To improve the heat transfer ability and wear resistance of drying cylinders in paper production machines, a series of Fe_87?x Cr₁₃B _x (x = 1 wt.%, 1.5 wt.%, 2 wt.%, 2.5 wt.%, 3 wt.%, and 4 wt.%) cored wires have been produced and used to prepare coatings by wire-arc spraying, in comparison with conventional X30Cr13 solid wire. All coatings presented dense layered structure with porosity of around 4%. The boron content in the cored wires significantly affected the thermal conductivity of the coating, which is attributed to the combined effects of the crystal structure, grain size, and oxide content of the coating. In the investigated range, the coating with 2 wt.% boron content exhibited the highest thermal conductivity, reaching 8.83 W/m-K, greater than that of X30Cr13 coating (5.45 W/m-K). Furthermore, the microhardness and relative wear resistance of the FeCrB coatings obtained from cored wires with boron addition were greatly increased compared with commercial X30Cr13 coating. Therefore, wire-arc-sprayed FeCrB coating has promise as an effective and economic approach to improve the heat transfer behavior and wear resistance of drying cylinders in the paper industry.     

Corrosion Behavior and Microhardness of Ni-P-SiO<Subscript>2</Subscript>-Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Nano-composite Coatings on Magnesium Alloy

In the present work, nano-composites of Ni-P-SiO₂-Al₂O₃ were coated on AZ91HP magnesium alloy. The surface morphology of the nano-composite coating was studied by field emission scanning electron microscopy (FESEM). The amount of SiO₂ in the coating was determined by energy-dispersive analysis of x-ray (EDX), and the crystalline structure of the coating was examined by x-ray diffractometer (XRD). All the experiments concerning the corrosion behavior of the coating carried out in 3.5 wt.% NaCl solution and evaluated by electrochemical impedance spectroscopy (EIS) and polarization technique. The results showed that an incorporation of SiO₂ and Al₂O₃ in Ni-P coating at the SiO₂ concentration of 10 g/Land 14 g/LAl₂O₃ led to the lowest corrosion rate (i _corr = 1.3 µA/cm²), the most positive E _corr and maximum microhardness (496 VH). Furthermore, Ni-P-SiO₂-Al₂O₃ nano-composite coating possesses less porosity than that in Ni-P coating, resulting in improving corrosion resistance.     

Corrosion and Wear Behaviors of Cr-Doped Diamond-Like Carbon Coatings

A combination of plasma-enhanced chemical vapor deposition and magnetron sputtering techniques has been employed to deposit chromium-doped diamond-like carbon (DLC) coatings on stainless steel, silicon and glass substrates. The concentrations of Cr in the coatings are varied by changing the parameters of the bipolar pulsed power supply and the argon/acetylene gas composition. The coatings have been studied for composition, morphology, surface nature, nanohardness, corrosion resistance and wear resistance properties. The changes in I _D /I _G ratio with Cr concentrations have been obtained from Raman spectroscopy studies. Ratio decreases with an increase in Cr concentration, and it has been found to increase at higher Cr concentration, indicating the disorder in the coating. Carbide is formed in Cr-doped DLC coatings as observed from XPS studies. There is a decrease in sp ³/sp ² ratios with an increase in Cr concentration, and it increases again at higher Cr concentration. Nanohardness studies show no clear dependence of hardness on Cr concentration. DLC coatings with lower Cr contents have demonstrated better corrosion resistance with better passive behavior in 3.5% NaCl solution, and corrosion potential is observed to move toward nobler (more positive) values. A low coefficient of friction (0.15) at different loads is observed from reciprocating wear studies. Lower wear volume is found at all loads on the Cr-doped DLC coatings. Wear mechanism changes from abrasive wear on the substrate to adhesive wear on the coating.     

Prospects of In-Situ <Emphasis Type="Italic">α</Emphasis>-Al<Subscript>2</Subscript>O<Subscript>3</Subscript> as an Inoculant in Aluminum: A Feasibility Study

In-situ α-Al₂O₃ was successfully synthesized and dispersed in Al alloy using B₂O₃ and ultrasonication-aided liquid mixing technique. Microstructure analysis identified α-Al₂O₃ as the most common phase in the composite master alloy, whereas AlB₁₂ was frequently observed and AlB₂ was rarely found in the alloy. Grain refinement analysis of selected Al alloys registered a transition of columnar to equiaxial grains of α-Al with the inoculation of the master alloy and ultrasonication treatment. Similarly, an improvement in the mechanical properties of A357 alloy was observed with the combination of inoculation and ultrasonication treatment.     

Designed fabrication of hard CrCr2O3Cr7C3 nanocomposite coatings for anti-wear application

Nanocrystalline CrCr₂O₃Cr₇C₃ composite coatings were fabricated by electrodeposition followed by thermal treatment. The structures of coatings were investigated using high-resolution transmission electron microscopy and X-ray diffraction analysis. The composition, elemental chemical state, mechanical properties and wear resistance of coatings were determined using energy dispersive X-ray spectroscopy, X-ray photoelectron spectroscopy, nanoindentation and oscillating friction-wear testing, respectively. Wear tracks were observed by scanning electron microscopy. The results show that the as-deposited coating exhibits amorphous structure. The subsequent thermal treatment at 600 °C induces the crystallization and the generation of nanoscale Cr₂O₃ and Cr₇C₃ particles in the Cr-matrix, which results in the hardness of the coating increasing to 21 GPa with slight increase in elastic modulus. Owing to the compromise between high hardness and low elastic modulus, the obtained CrCr₂O₃Cr₇C₃ composite coating exhibits excellent wear resistance.     

Phase Equilibria of the Ternary Al-Cu-Zn Alloys on Al-Zn Rich Side

Phase equilibria of the Al-Cu-Zn system on Al-Zn rich side was experimentally determined with 16 alloys annealed at 360 °C. The annealed alloys were examined by means of x-ray diffraction, electron probe microanalysis and differential scanning calorimetry. Five single-phase regions and seven two-phase regions as well as three three-phase regions, i.e. α-(Al)?+?θ-Al₂Cu?+?τ′-Al₄Cu₃Zn, α-(Al)?+?τ′-Al₄Cu₃Zn?+?ε-CuZn₄ and α-(Al)?+?ε-CuZn₄?+?(Zn), were determined. The partial isothermal section of the Al-Cu-Zn system on Al-Zn rich side at 360 °C was constructed based on the obtained experimental data in this work. It was observed that the solid solution phase α-(Al) would easily decompose into ε-CuZn₄, (Zn) and α′-(Al) at the ambient temperature in the early stages. The ternary phase τ′-Al₄Cu₃Zn would form and ε-CuZn₄ would disappear gradually along with the extension of aging time.     

Effects of Substitution of Fe by Mischmetal on Formation and Properties of Arc-Sprayed AlSi-Based Amorphous Coating

The influence of a partial substitution of Fe with Mischmetal [Ni₆₀RE₄₀ (wt.%), RE: rare earth including Ce; La; Nd and Pr] on the glass formation ability (GFA), mechanical properties and electrochemical corrosion behavior of arc-sprayed AlSiFe-based amorphous coatings has been investigated. It is revealed that partial substitution of Fe by Mischmetal slightly debases the GFA and mechanical properties of the AlSiFe amorphous coating because of the selective oxidation of RE elements. With Mischmetal substitution, the amorphous fraction, onset crystallization temperature and microhardness of the coating decrease to 64.3%, 306 °C, and 338.7 Hv₁₀₀, respectively. Compared with a crystalline aluminum alloy and coating, the coating with Mischmetal substitution still has a prominent wear and corrosion resistance. The relative wear resistance of the coating with Mischmetal substitution is about 2.5 times than that of the 6061-Al alloy under the same dry sliding testing condition. In 0.6 M NaCl aqueous solution, the coating with Mischmetal substitution manifests a lower I_corr, higher E_corr and E_p values in polarization curves and bigger fitted R_ct value in EIS plots than does the as-sprayed crystalline Al coating.     

Adsorption properties of aluminum oxide modified with Co and CoO particles

Adsorption properties of γ-Al₂O₃ modified with Co (5 and 10 wt %) and Co (5 wt %) species are investigated by dynamic adsorption. N-hexane, n-heptane, n-octane, benzene, toluene, ethylbenzene, chloroform, and diethyl ether were used as test adsorbates. Adsorption isotherms were measured, and isosteric adsorption heats were calculated for the indicated sorbates. It was shown that the adsorption isotherms of all the adsorbates and at all the temperatures of measurements on γ-Al₂O₃ modified with Co (5 wt %) and CoO (5 wt %) nanoparticles located above that recorded for the initial γ-Al₂O₃ sample. It was established that the surface of modified γ-Al₂O₃ possessed mainly electron-accepting properties. The 5% Со/γ-Al₂O₃ and 5% СоO/γ-Al₂O₃ nanocomposites exhibited the greatest adsorption capacity relative to aromatic hydrocarbons.     

Wear Resistance Enhancement of Ti-6Al-4 V Alloy by Applying Zr-Modified Silicide Coatings

Zr-modified silicide coatings were prepared on Ti-6Al-4 V alloy by pack cementation process to enhance its wear resistance. The microstructure and wear properties of the substrate and the coatings were comparatively investigated using GCr15 and Al₂O₃ as the counterparts under different sliding loads. The obtained Zr-modified silicide coating had a multilayer structure, consisting of a thick (Ti,X)Si₂ (X represents Al, Zr and V elements) outer layer, a TiSi middle layer and a Ti₅Si₄ + Ti₅Si₃ inner layer. The micro-hardness of the coating was much higher than the substrate and displayed a decrease tendency from the coating surface to the interior. Sliding against either GCr15 or Al₂O₃ balls, the coatings showed superior anti-friction property to the Ti-6Al-4 V alloy, as confirmed by its much lower wear rate under each employed sliding condition.     

Microstructure Evolution of Plasma-Sprayed MoSi<Subscript>2</Subscript> Coating at RT-1200 °C in Air

In this work, the phase composition and microstructure evolution of vacuum plasma-sprayed MoSi₂ coating between room temperature and 1200 °C in air was evaluated and characterized. The results showed that hexagonal MoSi₂ (h-MoSi₂) became the main phase in the deposited coating, which remained even after 50 h oxidation at 500 °C, exhibiting excellent thermal stability. MoO₃ bundles and SiO₂ clusters were generated by consuming tetragonal MoSi₂ (t-MoSi₂) after 1 h, and white powders formed on the coating’s surface after 10-h exposure to air at 500 °C. Most h-MoSi₂ transformed to t-MoSi₂ at 800 °C; moreover, a protective silica layer formed on the coating surface. Similar phenomenon was observed for the coating exposed to 1000 °C where grain growth also occurred. Vacuum heat treatment at 900 °C effectively improved the thermal stability of the MoSi₂ coating. The formation of silica layer alleviated negative effects of structural defects and helped the MoSi₂ coating serve as a protective coating for varied substrates.     

Tribological Behavior of Aluminum Slurry Coating on 300M Steel

Al slurry coatings, an alternative of Cd coating to protect against corrosion in the aerospace industry, are currently being explored to satisfy the stringent technology and safety requirements for aeronautical applications. The results of salt fog corrosion exposure, fluid corrosion exposure (immersion), humidity resistance, electrical conductivity, galvanic corrosion, embrittlement, and fatigue indicate that Al slurry coatings can be used as an alternative of Cd coatings. However, the tribological property of Al slurry coatings has still not been investigated. Two types of aluminum slurry coatings on 300M steel were produced using the innovative technological process and characterized by scanning electron microscope, nanoindentation tests, and adhesion tests. The H/E and H ³/E ² ratios of the two-layer Al slurry-coated sample were almost four times higher than the Cd-Ti plating-coated sample. The dry wear test results show that the friction coefficient of the two-layer Al slurry coating independently from the load was lower than the Cd-Ti plating. The width of the wear track of the two-layer Al slurry coating was significantly narrower, only 62% of the Cd-Ti plating wear scar. Compared to the Cd-Ti plating, an excellent wear resistance of the two-layer Al slurry coating can be attributed to its high resistance to plastic deformation and good load-bearing capacity. The results indicate that the two-layer Al slurry coating is an excellent alternative to Cd coatings in the aerospace industry.     

High-Temperature Oxidation of Nickel-Based Cermet Coatings Containing WC and Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Nanosized Particles

This paper investigates the high-temperature oxidation of cermet coatings composed of two types of nanosized particles (WC and a mixture of WC and Al₂O₃) incorporated in nickel and produced by co-electrodeposition. For this purpose, high-temperature oxidation tests were conducted at three temperatures (500, 600, and 700 °C) in dry air with 6 time intervals up to 96 h and mass changes at each specific time interval was measured. Statistical techniques were used to calculate the oxidation rate constants (k) and growth-rate time constants (a) for all coatings. The confidence intervals associated with tests were also calculated. The results showed linear to sub-parabolic oxidation rates for coatings composed of only WC particles and sub-liner to liner oxidation rates for coating with both WC and Al₂O₃ particles. The reduction in oxidation rates for coatings with both WC and Al₂O₃ particles were correlated to the addition of Al₂O₃ particles in the matrix.     

Corrosion and Wear Response of Oxide-Reinforced Nickel Composite Coatings

Various grades of fuels are used in automobiles, as a result the engine components are continuously subjected to simultaneous action of corrosion and wear. Ni-SiC composite coating is the most widely investigated and commercialized wear-resistant coating in the automotive industry. However, this coating cannot be used at temperatures above 450 °C due to the tendency of SiC to react with Ni and form brittle silicides. An alternate approach is to use oxide-reinforced coatings. In the present study, zirconia, ZrO₂ and, yttria-stabilized zirconia, YSZ-reinforced Ni composite coatings have been developed by electrodeposition method. It was observed from the microhardness studies that there is no significant difference in the values for Ni-SiC and Ni-ZrO₂ coatings. The corrosion behavior was evaluated using polarization and electrochemical impedance studies. The studies showed that oxide particle-reinforced Ni coatings possessed better corrosion resistance due to their lower corrosion current density, I _corr. Tribo-corrosion studies were carried out to understand the synergistic effect of wear and corrosion on the performance of Ni-based composite coatings in 0.5 M Na₂SO₄. Among various composite coatings, Ni-YSZ exhibited less material loss thereby showing better tribo-corrosion behavior.     

Development and Optimization of Tailored Composite TBC Design Architectures for Improved Erosion Durability

Rare-earth pyrochlores, RE₂Zr₂O₇, have been identified as potential thermal barrier coating (TBC) materials due to their attractive thermal properties and CMAS resistance. However, they possess a low fracture toughness which results in poor erosion durability/foreign object damage resistance. This research focuses on the development of tailored composite air plasma spray (APS) TBC design architectures utilizing a t′ Low-k secondary toughening phase (ZrO₂-2Y₂O₃-1Gd₂O₃-1Yb₂O₃; mol.%) to enhance the erosion durability of a hyper-stoichiometric pyrochlore, NZO (ZrO₂-25Nd₂O₃-5Y₂O₃-5Yb₂O₃; mol.%). In this study, composite coatings have been deposited with 30, 50, and 70% (wt.%) t′ Low-k toughening phase in a horizontally aligned lamellar morphology which enhances the toughening response of the coating. The coatings were characterized via SEM and XRD and were tested for erosion durability before and after isothermal heat treatment at 1100 °C. Analysis with mixing laws indicated improved erosion performance; however, a lack of long-term thermal stability was shown via isothermal heat treatments at 1316 °C. An impact stress analysis was performed using finite element analysis of a coating cross section, representing the first microstructurally realistic study of mechanical properties of TBCs with the results correlating well with observed behavior.     

Effect of Al,Si, and Cr on the thermal stability and high-temperature oxidation resistance of coatings based on titanium boronitride

The thermal stability and resistance to high-temperature oxidation of multicomponent nanostructured coatings in the Ti-X-B-N (X = Al, Si, Cr) system have been studied using X-ray diffraction analysis, X-ray photoelectron spectroscopy, secondary-ion mass spectroscopy, and transmission electron microscopy. The hardness, elastic modulus, elastic recovery, friction coefficient, wear rate, and adhesion strength of the coatings have been determined. It has been established that Ti-B-N and Ti-Cr-B-N coatings exhibit a stable nanostructure and high stable mechanical and tribological properties up to 1000°C. The coatings with an fcc structure can be also employed as barrier layers preventing diffusion of metal atoms from the substrate. It has been shown that the high resistance to high-temperature oxidation of Ti-Cr-B-N and Ti-Al-Si-B-N coatings is connected with the fact that protective oxide layers based on (Ti,Cr)BO₃ and Ti _x Al _y SiO _z are formed on their surface.     

Determination of Triaxial Residual Stress in Plasma-Sprayed Hydroxyapatite (HAp) Deposited on Titanium Substrate by X-ray Diffraction

Measurement of residual stress in plasma-sprayed coating is of key importance to optimize their microstructure and mechanical properties. In this study, the x-ray diffraction analysis was carried out using the sin²ψ method to evaluate the residual stress distribution of hydroxyapatite (HAp) coatings produced on titanium substrate by atmospheric plasma spraying (APS) and vacuum plasma spraying (VPS). The sin²ψ method measured strains at different tilt ψ and rotating φ angles around the specimen surface normal. A non-uniform and inhomogeneous stress distribution was present in the both coatings. The measured strain ε_ψφ is plotted versus sin²ψ, showing a nonlinear (elliptical) behavior, which indicates the presence of inhomogeneous triaxial stress distributions within coating, due to the crystalline anisotropy, inhomogeneous cooling rate or solidification of the molten particles. The normal stress values within both HAp coatings produced were found to be tensile in nature, but the values of tensile stresses are significantly higher in APS coating than those values obtained for VPS coating.     

Oxidation of La–Sr–Mn-Coated Interconnector Alloys for Steam Electrolysis Under Pressure in Pure Oxygen and in Pure Steam

Pressurized steam electrolysis enables an efficient conversion of electric power from renewable energy sources into hydrogen for power-to-liquids processes. The interconnector material Crofer 22 APU, uncoated and coated by La_1?x Sr _x MnO₃ (LSM), deposited by thermal spray and by roll coating was studied in pure water vapor and pure oxygen at 850 °C and 30 bar. The uncoated Crofer 22 APU forms in both atmospheres a homogeneous oxide scale from an inner Cr₂O₃ and an outer MnCr₂O₄ layer. The chromia is locally undergrown by pits of MnCr₂O₄. With the LSM coating, the oxide scale is notably thinner in water vapor and the formation of pits is significantly reduced. In oxygen, this effect of the LSM coating is less pronounced. Chromium from volatile species was detected in the LSM coating, more in oxygen than in water vapor. After 3000 h in pure oxygen, Crofer 22 APU with thermally sprayed LSM shows breakaway oxidation.     

Supersonic Plasma Spray Deposition of CoNiCrAlY Coatings on Ti-6Al-4V Alloy

Plasma spray is a versatile technology used for production of environmental and thermal barrier coatings, mainly in the aerospace, gas turbine, and automotive industries, with potential application in the renewable energy industry. New plasma spray technologies have been developed recently to produce high-quality coatings as an alternative to the costly low-pressure plasma-spray process. In this work, we studied the properties of as-sprayed CoNiCrAlY coatings deposited on Ti-6Al-4V substrate with smooth surface (R _a = 0.8 μm) by means of a plasma torch operating in supersonic regime at atmospheric pressure. The CoNiCrAlY coatings were evaluated in terms of their surface roughness, microstructure, instrumented indentation, and phase content. Static and dynamic depositions were investigated to examine their effect on coating characteristics. Results show that the substrate surface velocity has a major influence on the coating properties. The sprayed CoNiCrAlY coatings exhibit low roughness (R _a of 5.7 μm), low porosity (0.8%), excellent mechanical properties (H _it = 6.1 GPa, E _it = 155 GPa), and elevated interface toughness (2.4 MPa m^1/2).