Corrosion fatigue behavior of a steel with sprayed coatings

This paper describes the corrosion fatigue behavior and fracture mechanisms of a steel with different sprayed coatings. Rotating bending fatigue tests were conducted in 3% NaCl solution using specimens of a medium carbon steel with sprayed coatings of a ceramic (Cr₂O₃), a cermet (WC-12%Co) and two metals (Ni-11 % P and Al-2% Zn). The corrosion fatigue process was basically the same for ceramic, cermet, and Ni-11 % P sprayed specimens. That is, the corrosive media could be supplied from the specimen surface to the substrate through cracks initiated during fatigue cycling and/or pores in the coatings, and thus corrosion pits were generated followed by subsequent crack initiation and growth in the substrate. The corrosion fatigue strength of ceramic sprayed specimens was slightly improved compared to that of the substrate steel because the under-coating (Ni-5%A1) could impede the penetration of the corrosive media although the ceramic coating had a poor resistance to cracking under cyclic loading. Cermet sprayed specimens also exhibited improved corrosion fatigue strength because of the high resistance to cracking and the low volume fraction of pores of the coating. In Ni-11 % Psprayed specimens, cracks were initiated in the coating even at low stress levels; thus the corrosion fatigue strength was the same as that of the substrate. Anodic dissolution took place in Al-2 % Zn coating because the coating was electrochemically poor, and thus the substrate was cathodically protected. Therefore, the corrosion fatigue strength of Al-2 % Zn sprayed specimens was enhanced to as high as the fatigue strength of the substrate in room air. Based on the experimental results, a dual-layer coating consisting of WC-12%Co and Al-2%Zn was fatigue tested. The coating was effective at low stress levels and exhibited long life under conditions where corrosion fatigue strength was critical.     

Accumulation of microstructural damage due to fatigue of high-strength aluminum alloys

The microstructural features of aluminum alloy 7050-T7451 in the vicinity of fatigue cracks and on the crack path were studied to determine which of these features influence fatigue crack propagation. The studies included characterization of the full spectrum of microstructural and fracture surface features— from the largest (e.g., roughness and grain type) to the smallest (e.g., second-phase particles and dislocations). Of all the features studied, only the second-phase particles were shown to have a definite influence by causing crack deflection. The number of particles encountered by the fatigue cracks were significantly higher than the expected average. The fatigue crack path was predominately transgranular, and there was no change in the dislocation and precipitation structures in the crack-affected zone.     

涂覆WC-17Co涂层的Ni718合金在不同环境温度中的疲劳性能

利用超音速火焰喷涂技术在Ni718合金表面制备WC-17Co涂层.利用反复弯曲试验分析25,150,300℃条件下涂覆WC-17Co涂层Ni718合金疲劳性能,利用扫描电镜、X射线衍射仪分析涂层的断口形貌和相组成,并利用剥层法测量涂层中残余应力分布.结果表明,相同应变量条件下试样的疲劳寿命随着温度的升高而降低;循环载荷作用下裂纹由涂层表面产生,向基体方向扩展,最终形成整体断裂;室温至300℃温度范围内,涂层不会发生相变,但是随环境温度上升涂层中的残余压应力呈现下降趋势,这种趋势使得涂层中裂纹的扩展速度增加,最终导致疲劳寿命下降.     

Improvement of wear resistance of plasma-sprayed molybdenum blend coatings

The wear resistance of plasma sprayed molybdenum blend coatings applicable to synchronizer rings or piston rings was investigated in this study. Four spray powders, one of which was pure molybdenum and the others blended powders of bronze and aluminum-silicon alloy powders mixed with molybdenum powders, were sprayed on a low-carbon steel substrate by atmospheric plasma spraying. Microstructural analysis of the coatings showed that the phases formed during spraying were relatively homogeneously distributed in the molybdenum matrix. The wear test results revealed that the wear rate of all the coatings increased with increasing wear load and that the blended coatings exhibited better wear resistance than the pure molybdenum coating, although the hardness was lower. In the pure molybdenum coatings, splats were readily fractured, or cracks were initiated between splats under high wear loads, thereby leading to the decrease in wear resistance. On the other hand, the molybdenum coating blended with bronze and aluminum-silicon alloy powders exhibited excellent wear resistance because hard phases such as CuAl₂ and Cu₉Al₄ formed inside the coating.     

Influence of Substrate Material on Plain Fatigue and Fretting Fatigue Behavior of Detonation Gun Sprayed Cu-Ni-In Coating

Cu-Ni-In coating was formulated on two substrate materials—Ti-alloy (Ti-6Al-4V) and Al-alloy (AA 6063) fatigue test specimens using detonation gun (D-gun) spray process. Coating on both substrates was dense with low porosity, high hardness, and high surface roughness. Relatively higher surface compressive residual stress was present at the coating on Ti-alloy specimens. In case of the coating on Al-alloy samples, tensile residual stress was also present in some places. Uniaxial plain fatigue and fretting fatigue experiments were conducted on uncoated and coated specimens. The detrimental effect of life reduction due to fretting was relatively larger in the Al-alloy compared to the Ti-alloy. While Cu-Ni-In coating was found to be beneficial on the Ti-alloy, it was deleterious on the Al-alloy substrate under both plain fatigue and fretting fatigue loading. The results were explained in terms of differences in the values of surface hardness, surface roughness, surface residual stress, and friction stress.     

Reactive plasma spraying of wear-resistant coatings

A method for producing wear-resistant, carbide-reinforced coatings has been investigated. A conventional low-pressure plasma gun has been modified with a downstream reactor into which carbon-containing gases are mixed, heated, and disassociated. The disassociated gas ions—H* and C* —are subsequently brought into contact with heated, molten metal matrix powders. Experiments with NiCr/Ti blends and W powders have shown that uniformly dispersed carbides such as, TiC, Cr^Cy, WC, and W2C were formed in situ on the metal precursor powders during deposition. The in situ formed particles, being formed directly from the matrices, show excellent matrix cohesion and lead to high and uniform deposit microhardnesses. The process is described and several evaluations of materials, reactive gases, and spray conditions are reported. Microanalysis of the coatings are presented, microhardness values are reported, and XRD identifies the in situ formed phases.     

LY12铝合金微弧氧化涂层组织结构对基体疲劳性能的影响

在硅酸盐体系电解液中于铝合金表面制备出不同厚度的微弧氧化涂层,研究涂层厚度对基体疲劳寿命的影响,并揭示疲劳损伤机制.采用XRD、SEM、EDS等分析手段分析涂层的物相与组织结构.用810 Material Test System 疲劳试验机评价涂层试样的疲劳寿命.结果表明,铝合金微弧氧化涂层主要由γ-Al_2O_3和a-Al_2O_3组成,涂层内层致密,表面多微孔.随氧化时间延长,涂层厚度增大,但表面粗糙度增加.疲劳测试结果表明,微弧氧化涂层会降低基底铝合金的疲劳寿命,涂层厚度增加,疲劳寿命下降显著.相对于基体铝合金,涂层厚度为10,18,30 mm的试样,疲劳寿命分别下降了4.4%,8.5%,32.2%.疲劳断口分析认为,涂层局部过度长入基体产生缺陷部位,在循环载荷作用下,容易产生应力集中,从而萌生疲劳源,使铝合金的疲劳寿命下降.     

Fatigue life improvements of the AISI 304 stainless steel ground surfaces by wire brushing

The surface and subsurface integrity of metallic ground components is usually characterized by an induced tensile residual stress, which has a detrimental effect on the fatigue life of these components. In particular, it tends to accelerate the initiation and growth of the fatigue cracks. In this investigation, to deliberately generate compressive residual stresses into the ground surfaces of the AISI 304 stainless steel (SS), wire brushing was applied. It was found that under the experimental conditions selected in this investigation, while the surface roughness was slightly improved by the brushing process, the surface residual stress shifted from a tensile stress (σ_‖=+450 MPa) to a compressive stress (σ_‖=−435 MPa). On the other hand, the work-hardened deformation layer was almost two times deeper after wire brushing. Concerning the fatigue life, an improvement of 26% in terms of endurance limit at 2×10⁶ cycles was realized. Scanning electron microscope (SEM) observations of the fatigue fracture location and size were carried out to explain the fatigue life improvement. It was found that the enhancement of the fatigue strength could be correlated with the distribution and location of the fatigue fracture nucleation sites. Concerning the ground surfaces, it was seen that the fatigue cracks initiated at the bottom of the grinding grooves and were particularly long (150–200 μm). However, the fatigue cracks at the brushed surfaces were shorter (20–40 μm) and appeared to initiate sideways to the plowed material caused by the wire brushing. The results of the wire-brushed surface characterization have shown that significant advantages can be realized regarding surface integrity by the application of this low-cost process compared to shot peening.     

Thermal fatigue of hot working steel after hybrid surface treatment

Abstract

The application of surface treatment methods like ion nitriding, physical vapour deposition (PVD) coatings and their combination in duplex treatments effectively reduces the occurrence of oxidation, corrosion, erosion and wear processes. However, it is still uncertain whether nitriding and duplex treatment have any real effect on the decrease in the nucleation and growth of thermal fatigue cracks on the surface. This paper presents the results of thermal fatigue investigations of a nitrided layer and different composite layers ‘nitrided layer/PVD coating’ (TiN, CrN and TiAlN) obtained on the EN X40CrMoV5·1 hot working steel. The ion nitrided only and three different duplex treated substrates were compared, based on the intensity of the thermal fatigue cracks observed after testing. The nitrided layer and composite layers investigated were obtained with the use of the hybrid surface treatment technology consisting of ion nitriding followed by arc evaporation coating deposition. Apparatus based on high frequency induction heating and water spray cooling was used for thermal fatigue tests under the following conditions: maximum temperature 600°C, minimum temperature 80°C and two different rates of thermal cycling: 500 and 1000. The thermal fatigue intensities of the nitrided layer and the three different composite layers were measured according to the surface crack density and crack length (i.e. penetration into the testpiece) after different numbers of thermal cycles. Finally, based on the results obtained, the influence of different PVD coatings in the composite layer on the increase in thermal fatigue resistance of hot working steel was discussed.     

Contact fatigue behavior of nano-ZrO2/Ni coating prepared by electro-brush plating

Nano-ZrO₂/Ni composite coatings were prepared through co-depositing nano-ZrO₂ particles and pure nickel by electro-brush plating (EBP). By analyzing the effects of microstructure, annealing and load on contact fatigue life, the contact fatigue behavior of the nano-ZrO₂/Ni EBP coating was investigated. Furthermore, the contact fatigue behaviors of the nano-ZrO₂/Ni EBP coating and the nickel EBP coating were compared. The results show that the nano-ZrO₂ particles in the as-deposited nano-ZrO₂/Ni EBP coating were partially conglomerated, and the microstructure of the annealed nano-ZrO₂/Ni EBP coating was finer. Under the as-deposited condition, the contact fatigue life of the nano-ZrO₂/Ni EBP coating was much lower than that of the nickel EBP coating. After the annealing process, the contact fatigue life of the nano-ZrO₂/Ni EBP coating was greatly increased and much higher than that of the nickel EBP coating. The scanning electron microscope (SEM) images of the fatigue fracture zones and the transmission electron microscope (TEM) images of microstructure of the deformation layer show that the annealing could improve the ductility of the nano-ZrO₂/Ni EBP coating, and the nano-ZrO₂ particles could restrain the propagation of the fatigue cracks, which contributed to the enhancement of the contact fatigue properties of the nano-ZrO₂/Ni EBP coating.     

Improved Protection Properties by Using Nanostructured Ceramic Powders for HVOF Coatings

The potential of the high-velocity oxy-fuel (HVOF) thermal spray process for reduced porosity in coatings compared to those produced by other ambient thermal spray processes is well known. The ability to produce high-density ceramic coatings offers potential in high-performance applications in the field of wear, corrosion resistance, and dielectric coatings. However, due to operational limit of the HVOF process to effectively melt the ceramic particles, the process—structure relationship must be well optimized. It has been also demonstrated that benefits from HVOF ceramic coatings can be obtained only if particles are melted enough and good lamella adhesion is produced. One strategy to improve melting of ceramic particles in relative low-flame temperatures of HVOF process is to modify particle crystal structure and composition. In this paper the effect of the powder manufacturing method and the composition on deposition efficiency of spray process as well as on the mechanical properties of the HVOF sprayed are studied. Effect of fuel gas, hydrogen vs. propane, was also demonstrated. Studied materials were alumina-, chromia-, and titania-based agglomerated powders. Coating properties such as microstructure, hardness, abrasive wear resistance, and relative fracture toughness were compared to the coating manufactured by using conventional fused and crushed powders. It can be concluded that powder size distribution and microstructure should be optimized to fulfill process requirements very carefully to produce coatings with high deposition efficiency, dense structure, improved fracture toughness, and adhesion.     

真空熔烧镍基合金—碳化铬复合涂层抗疲劳性能的研究

研究了用真空熔烧法制得的镍基合金－碳化铬复合涂层的热疲劳行为。结果表明,复合涂层的热疲劳行为与热循环上限温度、涂层厚度有关。随涂层厚度减薄,热疲劳抗力增加,随热循环上限温度升高,其热疲劳抗力降低,裂纹扩展由快到慢,最后停止,热疲劳裂纹有沿相界面开裂的特征,复合涂层具有高的抗氧化性。     

激光熔化沉积Ti-6Al-2Zr-Mo-V合金高周疲劳变形行为

研究激光熔化沉积Ti-6Al-2Zr-Mo-V合金在高周疲劳失效中的变形行为,并提出相应的变形机制.结果表明,激光沉积钛合金疲劳裂纹萌生和扩展中的变形行为都与其位错运动和滑移行为密切相关.疲劳裂纹扩展中的滑移主要沿两个滑移面进行;裂纹扩展亚表面存在大量二次裂纹.解释两种不同类型二次裂纹的形成机制和作用.分析粗大柱状晶晶界变形特征.     

Mechanical properties of the plasma-sprayed Al2O3/ZrSiO4 coatings

The mechanical properties of plasma-sprayed Al₂O₃/ZrSiO₄ coatings were investigated by indentation-based techniques. Two types of feedstock were used to prepare the coatings: spray-dried powders and plasma-spheroidized powders. A 100-kW direct current (d.c.) thermal plasma system was employed. The values obtained were found to exhibit a close relationship with the microstructure of the as-sprayed coatings, which composed of zircon, alumina, amorphous silica and tetragonal zirconia. The coatings produced with plasma-spheroidized powders had higher microhardness, Young's modulus and fracture toughness than that produced with the spray-dried powders. The coatings produced with plasma-spheroidized powders by a 100-kW computerized system at 15 kW of net plasma energy had the best mechanical properties, while those deposited at 19 kW of net plasma energy had the worst properties due to the high density of cracks in the coatings.     

Separating the effects of Ti3Al and silicide precipitates on the tensile and crack growth behavior at room temperature and 593 °C in a near-alpha titanium alloy

Aging of silicon-bearing, near-alpha titanium alloys produces two types of precipitate, Ti₃Al and (TiZr₆Si₃ (silicide). A postaging heat treatment that relies on the phenomenon of the critical ordering temperature is used to remove the Ti₃Al precipitate while leaving the silicide intact. Three materials—unaged (precipitate free), overaged (Ti₃Al plus silicide), and post aging heat treated (silicide only)— are compared. The objective is to identify the separate effects of the Ti₃Al and silicide precipitates on tensile and fatigue crack growth behavior at room temperature and 593 °C. The Ti₃Al precipitate is largely responsible for the increase in yield stress and for the decrease in ductility at both test temperatures. In contrast, the increase in room temperature fatigue crack growth rate associated with aging is attributed to the silicide, with Ti₃Al playing only a minor role. Aging produces a slight improvement in fatigue crack resistance at 593 °C, which also appears to be due to the presence of the silicide precipitate. Current address: Dept. of Materials Science and Engineering, University of Washington, Seattle, WA 98195, USA.     

Protective epoxy dispersion coating materials modified a posteriori with organophilized montmorillonites

Two types of paints (primer and topcoat) and coatings based on epoxy resin dispersions, water solution of polyamine hardener and a posteriori introduced four types of organophilized montmorillonite (mMMT) nanofillers: two commercial Nanofil-type (used as powders) and two pilot plant NanoBent-type products (in a powder and water-slurry form) were formulated and investigated. Pulverized organoclays were preliminarily incorporated (in various doses: 1, 2.5 and 5 wt.%) into the epoxy resin dispersions, filled mainly with iron oxides (primer) or the TiO₂/white filler (topcoat) using either a pearl-mill or a dissolver. Water-slurry of semihydrophilic modified montmorillonite was mixed with epoxy resin dispersions in the dissolver. The paints were applied on steel substrate and cured at room temperature. An influence of the method of introduction, handling form and type of mMMT on properties of epoxy dispersion paints and coatings has been investigated. In most cases coatings with semihydrophilic NanoBent-type nanofillers exhibited better properties than those with hydrophobic mMMT. Differences of barrier and mechanical features for primer, topcoat and primer/topcoat (multilayer) coatings based on results of water uptake, relative impedance, adhesion to steel, hardness and abrasion resistance tests, are discussed.     

Particle size effects on chemistry and structure of Al-Cu-Fe quasicrystalline coatings

Gas atomized Al₆₃Cu₂₅Fe₁₂ powders of varying size fractions were plasma sprayed onto hot (~600 °C) and cool (~25 °C) substrates using Mach I and subsonic plasma gun configurations. The chemical composition and phase contents of coatings were determined. Furthermore, coatings were annealed in vacuum at 700 °C for 2 h to observe phase changes. It was found that finer particles (e.g., <25 μm) tend to vaporize Al during spraying, which shifts the coating composition away from the quasicrystalline (ψ) single-phase region in the Al-Cu-Fe phase diagram. Coatings deposited on hot substrates were denser, richer in theψ phase, and harder than the corresponding coatings deposited onto cool substrates.     

HVOF热喷WC-12Co和Ni60涂层在不同攻角下的固体粒子冲蚀行为

目的 解决输气管线弯头冲蚀损伤而导致的刺漏问题。方法 采用超音速火焰喷涂（HVOF）方法在20#钢基材上分别制备WC-12Co和Ni60涂层。采用显微硬度计测试基材及涂层截面显微硬度。采用X射线衍射仪（XRD）分析涂层表面成分。采用自制喷射式气固冲蚀试验机开展30°、50°、90°3种攻角下固体粒子冲蚀（SPE）试验。采用扫描电子显微镜（SEM）观察SPE试验前后表面和截面的微观形貌,开展基材和2种涂层的SPE机理及冲蚀速率研究。结果 在30°攻角下,SPE机理以犁削为主,冲蚀速率受表面硬度的影响较大,20#钢冲蚀速率最大,而WC-12Co涂层的冲蚀速率最小;在50°攻角下,SPE机理为犁削和多冲疲劳混合机理,20#钢的冲蚀速率仍然最大,Ni60涂层和WC-12Co涂层的冲蚀速率相当,均较小;在90°攻角下,冲蚀机理以多冲疲劳损伤为主,WC-12Co涂层的缺陷较少,界面无裂纹,冲蚀速率最小,而Ni60涂层界面处存在裂纹,内部缺陷较多,抗疲劳性能差,冲蚀速率最高。结论 WC-12Co涂层在3种不同攻角下都表现出优异的抗冲蚀性能,为提升输气管线弯头抗冲蚀损伤提供了有力的保障。     

涂镀合金层的合金铸铁齿轮的接触疲劳强度研究

以齿轮为研究对象，用常用的辊子模拟方法，在Cu-Cr-P合金铸铁辊子试件表面分别涂镀Cu金属层、NiW合金层，然后与未涂镀的试件一起进行接触疲劳强度对比试验，共试验试件30对。试验结果表明：表面合金涂层能显著提高合金铸铁齿轮的接触疲劳寿命，文中同时分析了合金涂层的组织结构和性能。     

A Study of Ni-5wt.% Al coatings produced from different feedstock powder

Ten different Ni-5wt.%Al powders—three clad, done sintered, three water atomized, and three gas atomized—have been evaluated and plasma sprayed. The study focused on how manufacturing method, chemical composition, and particle size distribution of the powders affect the quality of the coating. Properties such as microstructure and mechanical behavior, as well as oxidation and corrosion resistance, are discussed. In conclusion, recommendations concerning the selection of powders for different applications are presented.