Structure and cavitation erosion behavior of HVOF sprayed multi-dimensional WC–10Co4Cr coating

A new kind of multi-dimensional WC–10Co4Cr coating which is composed of nano, submicron, micron WC grains and CoCr alloy, was developed by high velocity oxy-fuel (HVOF) spraying. Porosity, microhardness, fracture toughness and cavitation erosion resistance of the multi-dimensional coating were investigated in comparison with the bimodal and nanostructured WC–10Co4Cr coatings. Moreover, the cavitation erosion behavior and mechanism of the multi-dimensional coating were explored. Results show that HVOF sprayed multi-dimensional WC–10Co4Cr coating possesses low porosity (≤0.32%) and high fracture toughness without obvious nano WC decarburization during spraying. Furthermore, it is discovered that the multi-dimensional WC–10Co4Cr coating exhibits the best cavitation erosion resistance which is enhanced by approximately 28% and 34%, respectively, compared with the nanostructured and bimodal coatings in fresh water. The superior cavitation resistance of multi-dimensional WC–10Co4Cr coating may originate from the unique micro–nano structure and excellent properties, which can effectively obstruct the formation and propagation of cavitation erosion cracks.     

Wear and corrosion studies of Fe–B–Cr alloy coating on en 24 steel by HVOF thermal spray method

This work investigate the wear behavior of Fe–B–Cr coatings on medium carbon steel (EN24) substrate is used for several automotive parts. The high velocity oxy-fuel (HVOF) method was used to create the new crystalline coating of Fe–B–Cr (composition of 59%Fe–26%B–15%Cr in wt %) on a medium carbon steel substrate (AISI 4340). The characteristics of powder and coating are investigated using scanning electron microscopy (SEM) merged with energy dispersive spectroscopy (EDS), optical microscopy (OM) and thermogravmentric analysis (TGA) which were undertaken in the partial characterization of the coating. The phase contents of both powder and coatings were studied by X-ray diffraction (XRD). The coatings consist of melted and un-melted particles identified in the coatings. Moreover, oxides and micro-cracks were observed at the surface. The mechanical property of the coatings was characterized using a microhardness test. The hardness value increased three times more than the substrate. The coated surface showed lower levels of porosity. Moreover, the electrochemical investigation found Fe–B–Cr coating on medium carbon steel. The corrosion test was carried out in an environment with 0.5 M of NaCl, which showed that the corrosion resistance improved by coating.     

Effect of flow velocity on cavitation erosion behavior of HVOF sprayed WC-10Ni and WC-20Cr3C2–7Ni coatings

WC-10Ni and WC-20Cr₃C₂–7Ni coatings were deposited successively using high-velocity oxygen-fuel (HVOF) spraying. The microstructures and mechanical properties of the coatings were evaluated by X-ray diffraction (XRD), Field emission scanning electron microscopy (FESEM), energy dispersive X-ray spectroscopy (EDS), Vickers microhardness tester, and Ultra nanoindentation tester. The cavitation erosion behaviors of the coatings at different flow velocities were investigated by a rotating disk rig facility with bolt cavitator and circulating system. The results showed that the main phases in the WC-10Ni and WC-20Cr₃C₂–7Ni coatings were WC, W₂C, W, and WC, (W,Cr)₂C, respectively. Both coatings were dense and well bonded to the steel substrate. Despite higher porosity and elastic modulus (E) as well as slightly lower hardness (H), the WC-10Ni coating showed lower H/E, H³/E² and η values as well as cavitation erosion resistance at each flow velocity compared to the WC-20Cr₃C₂–7Ni coating. Both coatings exhibited an increase in the volume loss rates with increasing flow velocity, and the critical flow velocity of the WC-20Cr₃C₂–7Ni coating was in the region of 33.5 to 41.9 m·s⁻¹. The cavitation erosion failure mechanism of the WC-10Ni coatings was the brittle detachment of the WC particles, while cavitation pinholes, pits, cracks, craters, and massive exfoliation contributed to the evolution of the cavitation erosion processes of the WC-20Cr₃C₂–7Ni coating with the increase of the flow velocity.     

Microstructure and bend strength of WC–Co and steel joints

Abstract

Tungsten inert gas arc welding of WC–30 wt-%Co cemented carbide and steel was carried out using a variety of filler alloys. Precipitation of Fe₃W₃C occurred at the joint interface and this reduced the bend strength and toughness of the welded joint. The problem could be alleviated by adjusting the carbon concentration of the filler metal.     

Comparison between oxidation kinetics of HVOF sprayed WC–12Co and WC–10Co–4Cr coatings

In this study, the high temperature oxidation behavior of HVOF-sprayed WC–12Co and WC–10Co–4Cr coatings were investigated. To explore the oxidation mechanism, thermo-gravimetric analysis (TGA) was applied for isothermal treatments in the range of 500–800 °C for 3 h. X-ray diffraction (XRD) and scanning electron microscopy (SEM) were used to evaluate the structural changes and microstructural evolutions during oxidation tests. The TGA experiments showed negligible oxidation mass gains at 500 °C for both coatings. At higher temperatures, i.e. 700 and 800 °C, the oxidation mass gains of WC–12Co were found to be much higher than those for WC–10Co–4Cr coating, respectively. The higher oxidation resistance of WC–10Co–4Cr coating probably results from the formation of compact chromium oxide layers and higher MWO₄ type tungstate (M: Co and/or Cr) to tungsten trioxide (WO₃) ratios which provide lower porosity and consequently more efficient passivation effect against oxidation. The time dependent mass gain of WC–12Co coating obeys the linear law within temperature range of 600–800 °C with apparent oxidation activation energy of ~ 104 kJ/mol. As for the oxidation of WC–10Co–4Cr coating, a negligible deviation from linear law was observed possibly due to the presence of chromium oxide and higher tungstate to tungsten trioxide ratio which hinders the diffusion process through the scales compared with WC–12Co coating. The apparent activation energy for oxidation of the WC–10Co–4Cr coating was found to be ~ 121 kJ/mol.     

HIP diffusion bonding of P/M titanium alloy Ti-6Al-4V and stainless steel 1Cr18Ni9Ti

The HIP diffusion bonding of P/M titanium alloy Ti-6A1-4V and stainless steel 1Cr18Ni9Ti using pure Ni as intermediate layer was studied. Bonding joint with complex bonding interface was obtained by HIPing pre-alloyed Ti-6Al-4V powders and stainless steel 1Crl 8Ni9Ti in a vacuum canning. The joint strengths were examined and the characteristics of bonding joint were observed. The result shows that the maximized strength of HIP diffusion bonding between P/M titanium alloy Ti-6Al-4V and stainless steel 1Cr18Ni9Ti can be up to 388 MPa and the microstructure of bonding joint is acceptable.     

Microstructure and properties of WC–Co/3Cr13 joints brazed using Ni electroplated interlayer

The brazed joints of WC–Co cemented carbide and 3Cr13 stainless steel using Ni electroplated on Cu–Zn alloy as interlayer were investigated. The shear strength of the WC–Co/interlayer/3Cr13 joints increased firstly and then decreased with the increase of brazing temperature or brazing time. The maximum shear strength value of the brazed joints was 154 MPa at 1100 °C for 10 min. The characterizations of the WC–Co/interlayer/3Cr13 joints were studied by SEM, EDS and XRD. The results showed that the brazed joints fractured in the bulk WC–Co substrates near the interlayer. The added Ni promoted the formation of interdiffusion zone, which possessed positive effects on the bond strength of the WC–Co/interlayer/3Cr13 joints. Austenite solid solution was formed in the WC–Co/interlayer/3Cr13 joint, and the majority of austenite solid solution presented as columnar crystal. The number of austenite crystals on the WC–Co/interlayer interface was tremendously more than that on the interlayer/3Cr13 interface.     

Microjoining of Ti–Ni alloy and stainless steel using resistance brazing method aided by numerical simulation

A novel resistance brazing method aided by numerical simulation, in which the brazing is completed through several preliminary heatings and a subsequent final heating aided by the numerical simulation is presented. The preliminary heating is performed with a relatively low electric energy input so that the uniformity of the surface contact condition between two parts can be improved due to local melting and subsequent solidification and so that the electric current data can be acquired for preparing analytical conditions necessary to the numerical simulation. The final heating is performed with an energizing condition determined by the numerical simulation in advance. To prove the efficacy of the resistance brazing method aided by the numerical simulation, Ti–Ni alloy and type 304 stainless steel wires with diameters of 96 μm both were butt-joint brazed using Au–Cu brazing filler metal supplied with the individual metal plating. The brazed joints had tensile strengths ranging from 74 to 448 MPa in accordance with the energizing conditions.     

Solidification behaviour of laser welded type 21Cr–6Ni–9Mn stainless steel

The solidification mode and microstructures were characterised for various processing parameters for laser welding 21Cr–6Ni–9Mn stainless steel. Two heats with varying nitrogen content showed both primary ferrite and primary austenite solidification. Weld ferrite content varied from 1 to 11 vol.-%, and decreased as travel speed increased. Base metal nitrogen content affected both solidification mode and weld ferrite content. Nitrogen loss from the weld pool was found to range from 10 to 45%, and decreased with increasing travel speed. Solidification mode was dependent on both chemical composition and processing parameters. The solidification mode shifted from primary ferrite to primary austenite as travel speed increased due to increased undercooling. Solidification mode varied within welds with constant nitrogen content, and the change in solidification mode was attributed to changes in undercooling along the weld cross-section. It is proposed that the variation of solidification mode with undercooling is affected by both the solidification rate and thermal gradient.     

Role of Co Content on Densification and Microstructure of WC–Co Cemented Carbides Prepared by Selective Laser Melting

WC–Co cemented carbides, well-known as the conventional tooling materials, have not been successfully produced by one step additive manufacturing processes such as selective laser melting(SLM) yet. The microstructure evolution as well as WC grain growth behavior has rarely been investigated in detail during SLM process. In this study, the WC–Co cemented carbides with different Co contents(12–32 wt%) were prepared by optimized SLM processes for comparative investigation of densification behavior, microstructure characterization and mechanical property. The increase in Co content in feedstock carbide granules can improve the densification behavior during SLM process. The SLM processed WC-12 Co shows larger average WC grain size and higher percentage of coarser WC grains as compared with both WC-20 Co and WC-32 Co. The microstructure characterization, combined with finite element simulation, shows the WC grain growth mechanisms include agglomeration and dissolution-deposition of WC during SLM process and agglomeration of WC is an important mechanism especially for WC–Co cemented carbides with Co content as low as 12 wt%. The comparison between horizontal(perpendicular to the SLM laser beam) and vertical(parallel to the SLM laser beam) cross sections of carbides shows that SLM process introduces a certain degree of microstructure and mechanical behavior anisotropy for WC-12 Co, WC-20 Co, and WC-32 Co.     

Microstructure,microhardness and corrosion resistance of laser cladding Ni–WC coating on AlSi5Cu1Mg alloy

The microstructure, microhardness, and corrosion resistance of laser cladding Ni–WC coating on the surface of AlSi5Cu1Mg alloy were investigated by scanning electron microscopy, X-ray diffraction, microhardness testing, immersion corrosion testing, and electrochemical measurement. The results show that a smooth coating containing NiAl, Ni₃Al, M₇C₃, M₂₃C₆ phases (M=Ni, Al, Cr, W, Fe) and WC particles is prepared by laser cladding. Under a laser scanning speed of 120 mm/min, the microhardness of the cladding coating is 9–11 times that of AlSi5Cu1Mg, due to the synergistic effect of excellent metallurgical bond and newly formed carbides. The Ni–WC coating shows higher corrosion potential (−318.09 mV) and lower corrosion current density (12.33 μA/cm²) compared with the matrix. The crack-free, dense cladding coating obviously inhibits the penetration of Cl⁻ and H⁺, leading to the remarkedly improved corrosion resistance of cladding coating.     

Simulation of nitrogen transport and desorption in laser welds of 21Cr–6Ni–9Mn stainless steel

Loss of nitrogen is a concern when welding nitrogen strengthened stainless steel alloys. Building on the current understanding of the underlying mechanisms, a three-dimensional simulation of conduction mode laser weld pool development using the volume of fluid technique was developed. Weld pools formed by a moving Gaussian heat input for two different laser power densities were simulated and the transport and surface desorption of nitrogen was tracked using nitrogen macroparticles. The penetration depth and width of the weld pool predicted by the simulation was comparable to the data derived from macrographs of welds made on nitronic 40 alloy. Additionally, the 25–32% predicted decrease in nitrogen composition of the weld fusion zone by the new rate law is comparable to the literature.     

Effect of number of layers on erosion,corrosion, and wear resistance of multilayer Cr–N/Cr–Al–N coatings on AISI 630 stainless steel

In the present study, multilayered Cr–N/Cr–Al–N coatings were prepared by cathodic arc physical vapor deposition (PVD) with different numbers of layers and the same total thickness on AISI 630 steel in an attempt to improve the wear and erosion–corrosion resistance. Structural analysis of the coatings was performed by field scanning electron microscopy, X-ray diffraction (XRD), and energy-dispersive spectroscopy. Depth profiles and roughness parameters of worn surfaces were calculated after erosion and wear tests. XRD indicated that nitride compounds were formed in multilayer coatings by PVD. The Cr–N/Cr–Al–N coating exhibited superior corrosion resistance compared with AISI 630 substrate. The erosion–corrosion results revealed that the smoothest wear track with the minimum erosion rate and wear depth was obtained for five- and seven-layered coatings. The failure mechanism of the bare substrate was influenced by plastic deformation via cutting and plowing, while the failure mechanism for coated samples was chipping and delamination. According to the wear results, the multilayer coatings showed a lower friction coefficient and better surface morphology that demonstrated their high ability for wear protection.     

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 采用拉伸试验、金相分析和能谱分析等方法对1Cr18Ni9Ti不锈钢高压油管开裂的原因进行了分析。分析结果表明,高压油管的开裂是应力腐蚀开裂造成的。油管的固溶处理工艺不当,没有有效消除冷轧过程所产生的应力,材料处于严重的加工硬化状态,增加了材料的应力腐蚀敏感性。热轧过程产生的大量水蒸汽并含有氯和氧是引起高压油管应力腐蚀开裂的环境因素。     

1Cr18Ni9Ti不锈钢的锻造

介绍了1Cr18Ni9Ti不锈钢的特性、锻造工艺特点和热处理规范。     

Effect of phosphoric acid concentration on corrosion of Cr–Mn–N and Cr–Ni stainless steels

Phosphoric acid concentration (5–85%) effects on the corrosion behaviour of austenitic Fe–18Cr–12Mn–N steel have been studied by potentiodynamic polarisation measurements. After the anodic polarisation, both the film composition and the electronic structure have been investigated by X-ray photoelectron spectroscopy. The specimen surface examinations have been carried out by scanning electron microscopy. The results of the corrosion behaviour of the steel at issue have been compared to those relevant to two trademark materials [austenitic stainless steels AISI 304 (Fe–18Cr–9Ni) and X14AΓ15 (Fe–14Cr–15Mn–N)] and developed under the same test conditions.     

Liquid phase sintering and oxidation resistance of WC–Ni–Co–Cr cemented carbides

Fully dense WC–Ni–Co–Cr alloys have been consolidated via sinter HIP processing. Dilatometric tests show that shrinkage undergoes several accelerations and decelerations during heating, a phenomenon likely associated to the heterogeneous distribution of Cr in the binder phase. WC grain growth follows trends similar to those described for WC–Co hardmetals, increasing with the C activity and the amount of liquid phase of the cermets. Finally, the oxidation resistance of WC–Ni–Co–Cr cemented carbides is observed to improve as the metal content increases and the C content decreases. In both cases, the oxide layers present a higher proportion of (Co, Ni)WO₄ tungstates. The oxide scales formed on compositions with low metal content contain a higher amount of WO₃ oxide.     

1Cr18Ni9Ti 不锈钢表面电火花熔覆 WC 涂层特性研究

目的研究1Cr18Ni9Ti不锈钢经电火花强化后,WC涂层的显微组织和性能。方法采用电火花熔覆技术在不锈钢1Cr18Ni9Ti基体表面制备WC熔覆层,并分析熔覆层的表面形貌、显微组织、显微硬度、耐磨性,采用线性极化法研究熔覆层在3.5%(质量分数)Na Cl腐蚀溶液中的耐腐蚀性能。结果熔覆层组织均匀、连续、致密,与基体呈冶金结合。显微硬度最大值达到1680HV0.3,平均值为1336HV0.3,比不锈钢基材提高了4倍,耐磨性是不锈钢基材的4倍。在3.5%Na Cl腐蚀溶液中,熔覆层的自腐蚀电位较不锈钢减小了约165 m V,击破电位低于不锈钢基材,维钝电流密度高于不锈钢基材。结论熔覆层具有高硬度和高耐磨性能,磨损机理主要是粘着磨损和磨粒磨损,但在3.5%Na Cl腐蚀体系中,耐腐蚀性能低于1Cr18Ni9Ti不锈钢。