A comparative study of tribological behavior of plasma and D-gun sprayed coatings under different wear modes |
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Authors: | Sundararajan G Prasad K U M Rao D S Joshi S V |
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Affiliation: | (1) International Advanced Research Centre for Powder Metallurgy & New Materials, Opp. Balapur Village, RCI Road, R.R. District, 500 005 Hyderabad, India;(2) Defence Metallurgical Research Laboratory, P.O. Kanchanbagh, 500 058 Hyderabad, India |
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Abstract: | In recent years, thermal sprayed protective coatings have gained widespread acceptance for a variety of industrial applications.
A vast majority of these applications involve the use of thermal sprayed coatings to combat wear. While plasma spraying is
the most versatile variant of all the thermal spray processes, the detonation gun (D-gun) coatings have been a novelty until
recently because of their proprietary nature. The present study is aimed at comparing the tribological behavior of coatings
deposited using the two above techniques by focusing on some popular coating materials that are widely adopted for wear resistant
applications, namely, WC-12% Co, A12O3, and Cr3C2-MCr.
To enable a comprehensive comparison of the above indicated thermal spray techniques as well as coating materials, the deposited
coatings were extensively characterized employing microstructural evaluation, microhardness measurements, and XRD analysis
for phase constitution. The behavior of these coatings under different wear modes was also evaluated by determining their
tribological performance when subjected to solid particle erosion tests, rubber wheel sand abrasion tests, and pin-on-disk
sliding wear tests. The results from the above tests are discussed here. It is evident that the D-gun sprayed coatings consistently
exhibit denser microstructures and higher hardness values than their plasma sprayed counterparts. The D-gun coatings are also
found to unfailingly exhibit superior tribological performance superior to the corresponding plasma sprayed coatings in all
wear tests. Among all the coating materials studied, D-gun sprayed WC-12%Co, in general, yields the best performance under
different modes of wear, whereas plasma sprayed Al2O3 shows least wear resistance to every wear mode. |
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Keywords: | abrasion alumina coating chromium carbide-nickel chromium coating coatings d-gun coatings erosion plasma spray coatings sliding wear tribology tungsten carbide-cobalt coating |
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