Effect of heat treatment on the structure,cavitation erosion and erosion–corrosion behavior of Fe-based amorphous coatings

In this study, high-velocity oxygen-fuel sprayed amorphous coatings have been heat treated at various temperatures to form microstructures with crystalline phases. The structure, micro-hardness, cavitation erosion resistance and erosion–corrosion resistance of these coatings are compared. Crystalline phases are discovered in the coatings after heat treatments at 650 °C and 750 °C. The coating heat treated at 750 °C exhibits the poorest cavitation erosion resistance in 3.5 wt% NaCl solution among all coatings due to the degraded corrosion resistance. However, the hardness of the crystallized coating can reach 1000 Hv and the erosion–corrosion resistance of the heat treated coating is better than the untreated one.     

Cavitation erosion of Fe–Mn–Si–Cr shape memory alloys

Cavitation erosion tests of three Fe–Mn–Si–Cr shape memory alloys were carried out at speed 34 and 45 m/s using a rotating disc rig, and their cavitation damage has been investigated by comparison with a referring 13Cr–5Ni–Mo stainless steel used for hydraulic turbine vanes. The research results proved that the cavitation erosion of the Fe–Mn–Si–Cr shape memory alloys is a failure of low cycle fatigue and fracture propagates along grain boundaries. After 48 h cavitation erosion the cumulative mass losses of the studied alloys at speed 45 m/s are more than theirs at speed 34 m/s; however, the effect of velocity on cavitation damage of the Fe–Mn–Si–Cr alloys is much lower than that of 13Cr–5Ni–Mo stainless steel. The cumulative mass loss of the 13Cr–5Ni–Mo stainless steel are 26.3 mg at speed 45 m/s and 3.2 mg at speed 34 m/s, and the mass losses of the Fe–Mn–Si–Cr alloys are within the range of 3.6–7.3 mg at speed 45 m/s and 2.0–4.1 mg at speed 34 m/s. The surface elasticity of the Fe–Mn–Si–Cr shape memory alloys is better than that of the 13Cr–5Ni–Mo stainless steel, and the effect of surface elasticity on cavitation damage increases with velocity. The excellent surface elasticity of the cavitation-induced hexagonal closed-packed (h.c.p.) martensite plays a key role in contribution of phase transformation to the cavitation erosion resistance of the Fe–Mn–Si–Cr shape memory alloys. The cavitation damage of the studied alloys at speed 45 m/s mainly depends on their surface elasticity, and the variation of 48 h cumulative mass loss (Δm) as a function of the elastic depth (h_e) can be expressed as Δm=2.695+[1371.94/(4(h_e−46.83)²+12.751)] with a correlation factor of 0.99345.     

Effect of three nitriding treatments on tribological performance of 42CrAlMo7 steel in boundary lubrication

Evolution of friction and wear of 42CrAlMo7 steels with different nitriding processes was investigated during boundary-lubricated rolling–sliding tests. The wear behaviour of nitrided steel with a thin compound layer (produced by plasma nitriding and by gas nitriding followed by oxidation) was characterised by the early removal of the compound layer, and the wear resistance was thus, given by the underlying diffusion layer. In the case of the material with a thick compound layer (produced by gas nitriding) wear was restricted to the compound layer. In this material, at low applied load (300 N, i.e. 485 MPa of Hertzian pressure, in this work), after the removal of the external porous layer wear tended to be negligible. At high applied load (1000 N, 890 MPa), on the other hand, the wear rate became higher than that of the diffusion layer. The friction behaviour was followed by determining the λ-factor evolution during each test. For a given λ-factor, the friction coefficients at 300 N were lower than at 1000 N.     

Cavitation resistance of Cr–N coatings deposited on austenitic stainless steel at various temperatures

Cr–N coatings were deposited on austenitic stainless steel, X6CrNiTi18-10, by means of the cathodic arc evaporation method at three substrate temperatures: 200 °C, 350 °C and 500 °C. All coatings were found to have a composition of Cr(N), CrN and Cr₂N. The substrate temperature was found to have an influence on the hardness and Young's modulus of the Cr–N coatings. The investigation of nanocrystalline Cr–N coatings resistance to cavitation was performed in a cavitation tunnel with a slot cavitator and tap water as the medium. The estimated cavitation resistance parameters of the coatings were the incubation period of damage and total mass loss. It was found that the optimal coating cavitation resistance was deposited at 500 °C. The incubation period for the 500 °C deposition coating was the same as that of the uncoated X6CrNiTi18-10 steel, but the total mass loss was significantly lower than on the uncoated specimen. The scanning electron microscope analysis indicated that the damage process of the Cr–N coating mainly originates from the plastic deformation of the steel substrate–hard coating system, which appears by “micro-folding” of the surface. An increase of tensile stresses at the top of micro-folds initiates micro-cracks and delamination of Cr–N coating. The results of the investigation and the analysis indicate that the factors mainly responsible for cavitation resistance of the steel substrate/hard coating system are resistant to plastic deformation of the total system and coating adhesion.     

Sliding/rolling wear performance of plasma nitrided H11 hot working steel

H11 steel discs were tested by considering sliding/rolling friction under dry and lubricated conditions. The H11 discs were plasma nitrided at 500 °C and 550 °C for 9 h. Wear tests were conducted at different slip ratios of 1.79%, 10.53% and 22.22%. The test loads were 100 N, 150 N and 200 N. It was determined that plasma-nitrided H11 discs had a surface hardness of 1200–1400 HV0.1. Plasma nitriding produced wear performance much higher than those of the un-nitrided but hardened samples. The wear mechanism of the plasma-nitrided discs was a mixture of adhesive wear, abrasive wear and plastic yielding.     

Investigations on the effects of Nano-fluid in ECM of die steel

Formation of spikes in the electrochemically machined workpiece prevents to achieve the better performance of ElectroChemical Machining (ECM). Hence, this research work attempts to investigate the effects of Nano-fluid i.e. Nano Copper particles suspended NaCl electrolyte on the ECM of High carbon high chromium (HCHCr) die steel with a hardness of 63HRc. The influencing parameters are voltage, tool feed rate and electrolyte discharge rate with mixing levels. Seventy-two experiments have been conducted using Nano-fluid and plain NaCl electrolyte based on design of the experiment. The Nano Copper particles in the electrolyte break the gas layer at the inter electrode gap resulting in better MRR and surface roughness due to improved current density across the gap. A maximum MRR of 458.869 mm³/min and a minimum surface roughness of 1.39 μm Ra are obtained using Nano-fluid. The developed ANOVA models prove the significances of influencing factors in obtaining the better performance of ECM.     

Friction and wear characterization of sintered low alloyed chromium steels for structural components

Sintered and sintered/gas nitrided cylinders made of low alloyed chromium steel Astaloy CrL + 0.45 C at 7.25 g/cm³ density, have been tested for scuffing resistance and wear rate in a crossed cylinders test setup lubricated with a commercial SAE 10W40 engine oil at 90 °C. The results show large potential of 1 h gas nitriding of the sintered chromium steel cylinders. The nitrided cylinders experienced safe wear at 1000 MPa and scuffing at 1100 MPa at 2.5 m/s. At 0.5 and 0.1 m/s at least up to 800 MPa the wear was mild, as sintered chromium cylinders showed scuffing at pressure lower than 320 MPa and limited wear at 0.5 and 0.1 m/s.     

Nanocomposite polymer electrolyte based on rice starch/ionic liquid/TiO2 nanoparticles for solar cell application

Nanocomposite polymer electrolyte (NCPE) was prepared using solution cast technique. Rice starch (RS), lithium iodide (LiI), 1-methyl-3-propylimidazolium iodide (MPII) as ionic liquid and TiO₂ nanopowder (RS:LiI:MPII:TiO₂) were introduced to prepare the sample. The conductivity of 3.63 × 10⁻⁴ S/cm was achieved by introducing 30 wt.% of 1-methyl-3-propylimidazolium iodide (MPII) as ionic liquid and 2 wt.% of TiO₂. Temperature-dependent conductivity and dielectric behavior were analyzed in this work. Dye sensitized solar cell was fabricated using the nanocomposite film for this sample and analyzed.     

Research on improvement of machining accuracy of micro-rods with electrostatic induction feeding ECM

Micro-rods were machined by electrochemical machining using the electrostatic induction feeding method, with which ultra-short current pulse duration of several tens of ns can easily be obtained. A tungsten plate and stainless steel (SUS304) rod were used as the tool electrode and workpiece, respectively. To improve the machining accuracy, the machining characteristics when the workpiece is fed in the axial and radial directions were investigated using NaCl aqueous solution as the electrolyte. When fed in the axial direction, the machinable length of the micro-rods was found to peak at the optimum feed speed because of the influence of pitting corrosion and collision between electrodes. When the workpiece was fed in the radial direction, the influence of pitting corrosion decreased, however, the micro-rod was shortened with increasing feed distance in the radial direction because of the stray current flowing through the end of the micro-rod. The simulation results of the material removal process agreed qualitatively with experimental results. Next, machining characteristics were compared between the electrolytes, NaCl and NaNO₃ aqueous solutions, by feeding the workpiece in the axial direction. It was found that the influence of pitting corrosion was eliminated with the NaNO₃ aqueous solution, and there was no machinable length limitation with suitable feed speeds. In addition, the taper angle and gap width were smaller with the NaNO₃ aqueous solution, compared with those of the NaCl aqueous solution. Stainless steel micro-rods of 100 μm in diameter with a high aspect ratio of 20 were fabricated with the NaNO₃ aqueous solution. According to the preliminary research results, the machinable minimum diameter of the micro-rods was investigated and micro-rods with an average diameter of 9 μm and length of 78 μm were machined successfully.     

The effects of nickel and carbon concentrations on the wear resistance of Fe–Ni–C austenitic alloys

The effects of nickel and carbon concentrations on the wear resistance of Fe–xNi–yC (x = 14–20 wt.%, y = 0.6–1.0 wt.%) were investigated with respect to strain energy initiation of the martensitic transformation and hardness. The strain energy needed to initiate the martensitic transformation increased with increasing carbon and nickel concentrations, except in 1.0 wt.% C alloys. The wear resistance of the material decreased with increasing carbon concentration up to 0.9 wt.% C. This effect is most likely due to decrement of the martensite volume fraction with increasing carbon concentration induced by the incremental strain energy required to begin the martensitic transformation. In the case of 1.0 wt.% C, the improved wear resistance may be due to carbide precipitation.     

The capability of ultrafiltrated alkaline and organosolv oil palm (Elaeis guineensis) fronds lignin as green corrosion inhibitor for mild steel in 0.5 M HCl solution

The inhibitive effect of ultrafiltrated oil palm fronds (OPF) lignins on the corrosion of mild steel in 0.5 M HCl solution has been investigated by electrochemical impedance spectroscopy (EIS), potentiodynamic polarization (PP) and weight loss measurement. The presence of smaller lignin fractions reduces remarkably the corrosion rate of mild steel. The highest corrosion inhibition efficiency for all ultrafiltrated lignins were attained at maximum concentration of 500 ppm (IE_P.Soda: 87% > IE_P.Organosolv: 83% > IE_P.Kraft: 81%). The results from this corrosion test clearly reveal that all ultrafiltrated lignins behaved as a mixed-type inhibitor with predominant anodic (organosolv lignin) or cathodic (alkaline lignin) effectiveness. It was deduced that the inhibition process was spontaneous and the inhibitors were mainly physically adsorbed onto the mild steel surface.     

The lubrication of poly(etheretherketone) by an aqueous solution of nattokinase

Poly(etheretherketone) (PEEK) is a high strength and high temperature engineering polymer. However, its tribological performance is not very good in its pure form unless fillers or fibers are added to form composites. As polymers are often used for applications where traditional oil based lubrication may become an issue, water-based lubrication is desirable. This paper explores the lubrication performance of a natural fibrinolytic enzyme, nattokinase, found in fermented soybean (natto) in the aqueous solution. Pins of PEEK were slid against a steel disk in a pin-on-disk tester with the aqueous lubrication. The counterface disk material was a tool steel (R_a=0.37 μm). Tests were conducted at a rotational speed of 100 rpm and a normal load of 80 N. For comparison, tests were also conducted in NaCl solution. Nattokinase aqueous solution provides a coefficient of friction of 0.2 between PEEK and steel as compared to 0.3–0.35 for dry condition. The specific wear rates of PEEK for dry, deionized water, NaCl solution and aqueous nattokinase solution conditions were 10.5×10^?6, 51.6×10^?6, 228×10^?6 and 8.8×10^?6 mm³/N m, respectively. The fibrinolytic nattokinase enzyme provides lubricity with alkalinity reducing corrosion and eventually reducing wear.     

Improvement of cavitation erosion resistance of a duplex stainless steel through friction stir processing (FSP)

The cavitation erosion (CE) resistance of an UNS S32205 duplex stainless steel (DSS) was improved through microstructural modification using friction stir processing (FSP). As-received material was processed using 200 rpm and 100 mm/min spindle and travel speeds, respectively. The cavitation erosion tests were performed in a vibratory apparatus according to ASTM G32 standard. The incubation period, the maximum erosion rate and the variation of surface roughness during the tests are reported and the results are compared with those obtained for the base metal samples (BMS). The worn surfaces were characterized using roughness measurements and scanning electron microscopy (SEM). After a CE testing time of 10 h, FSP samples showed a 70% diminution of the mass loss when compared to the BMS. Moreover, a 200% enhancement of incubation time and 100% reduction in the erosion rate were achieved after FPS. The improvement of CE performance is related to the recrystallized and refined microstructure, as well as to the modification of the elongated α/γ interfaces.     

A study on erosion of upper bainitic ADI and PDI

Ductile iron containing ∼3.5 wt.% C and 2.1–4.2 wt.% Si (2.1, 2.8 and 4.2 wt.%) was studied. Three sets of specimens with differing Si contents were made into austempered ductile iron (ADI) and pearlite ductile iron (PDI) through heat treatment. These specimens were then eroded with Al₂O₃ particles and SiO₂ particles of 275–295 μm grit size to understand the relationship between erosion rate and microstructure. The ADI specimens were upper bainitic matrices that were austempered for different periods of time at 420 °C. The heat treatment of PDI was conducted at 870 or 930 °C for 1 h then forced air cooled or oil quenched to room temperature.Two types of wear curves, single peak curves and double peak curves, were found when plotting the erosion rate figures derived from the experimental results. 2.1 wt.% Si and 2.8 wt.% Si ADI tempered for a long period of time, due to their decreased retained austenite content and increased carbide content, had a single peak erosion rate curve. This embrittlement effect caused the impact angle of maximum erosion rate to increase from ∼30 to ∼45°. Decreasing the interspacing of the lamellae cementite promoted the hardness and improved the low-angle erosion wear resistance of PDI. The high hardness and brittleness of the matrix reduces the high-angle erosion resistance and the peak erosion rate occurs at a higher angle.For 2.1Si-ADI and 2.8Si-ADI tempered for a short duration, increasing the volume fraction of martensite in the matrix increases the erosion rate at an impact angle of 30°, but the maximum erosion rate is found at 75°. This results in a curve with a double peak. The double peak curve was also observed for high silicon ADI tempered for a long duration. The high solid solution hardness of 4.2Si-ADI, due to low retained austenite content and the presence of carbide in the matrix, results in poor erosion resistance. When this material is austempered for a long period, the erosion rate curve shifts from a single peak curve (30°) to a double peak curve (30°; 60°).     

Improved wear resistance in alumina-PTFE nanocomposites with irregular shaped nanoparticles

Past studies with PTFE nanocomposites showed up to 600× improvements in wear resistance over unfilled PTFE with the addition of Al₂O₃ nanoparticles. Irregular shaped nanoparticles are used in this study to increase the mechanical entanglement of PTFE fibrils with the filler. The tribological properties of 1, 2, 5 and 10 wt.% filled samples are evaluated under a normal pressure and sliding speed of 6.3 MPa and 50.8 mm/s, respectively. The wear resistance was found to improve 3000× over unfilled PTFE with the addition of 1 wt.% nanoparticles. The 5 wt.% sample had the lowest steady state wear rate of K = 1.3 × 10⁻⁷ mm³/N m and the lowest steady friction coefficient with μ = 0.21.     

Electrochemical behaviors of benzoic acid at polyaniline/CuGeO3 nanowire modified glassy carbon electrode

20 wt.% polyaniline/CuGeO₃ nanowires have been used as glassy carbon electrode (GCE) modified materials for electrochemical determination of benzoic acid (BA) in neutral solution. The intensities of the anodic cyclic voltammogram (CV) peaks increase linearly with the increase of BA concentration and scan rate. The linear range is 0.001–2 mM and detection limit is 0.96 μM and 0.47 μM for cvp1 and cvp2, respectively at a signal-to-noise ratio of 3. 20 wt.% polyaniline/CuGeO₃ nanowire modified GCE exhibits good stability and reproducibility. Polyaniline plays an important role in the electrochemical responses of BA at polyaniline/CuGeO₃ nanowire modified GCE. The detection limit decreases to 0.64 μM and 0.28 μM for cvp1 and cvp2, respectively with the polyaniline content increasing to 40 wt.%. Polyaniline/CuGeO₃ nanowire modified GCE exhibit better electrochemical performance than traditional methods.     

Corrosion inhibition efficiency and adsorption behavior of azomethine compounds at mild steel/hydrochloric acid interface

The adsorption and inhibition effect of azomethine compounds: PhN = NAC (COCH₃) = NC₆H₄Y {Y = OCH₃ (SB₁), CH₃ (SB₂), H (SB₃), Br (SB₄) and Y = Cl (SB₅)} on mild steel in 1 M HCl at 25 °C were studied using gravimetric measurements, cyclic voltammetry, UV–visible Spectrophotométrique and scanning electron microscope (SEM) methods. Inhibition efficiency was found to increase with the increase in azomethine SB₁-SB₅ concentration. The adsorption of each inhibitor on mild steel surface obeys Langmuir adsorption isotherm. The results of cyclic voltammetry showed that the presence of azomethine compound decreases the charge density in the transpassive region. The UV–visible absorption spectra of the solution containing the inhibitor after the immersion of mild steel specimen indicate the formation of a (SB₁-SB₅)-Fe complex. SEM and EDX observations confirmed the existence of protective inhibitor film on a metal surface.     

1-N-alkyl -3-methylimidazolium ionic liquids as neat lubricants and lubricant additives in steel–aluminium contacts

The influence of the alkyl chain length and of the anion on the lubricating ability has been studied for the room-temperature ionic liquids (IL) 1-n-alkyl-3-methylimidazolium X⁻ [X = PF₆; n = 6 (L-P106). X = BF₄; n = 2 (L102), 6 (L106), 8 (L108). X = CF₃SO₃; n = 2 (L-T102). X = (4-CH3C6H4SO3); n = 2 (L-To102)]. Neat IL have been used for AISI 52100 steel-ASTM 2011 aluminium contacts in pin-on-disk tests under variable sliding speed. While all IL give initial friction values lower than 0.15, real-time sharp friction increments related to tribochemical processes have been observed for L102 and L-P106, at room-temperature and at 100 °C. Electronic microscopy (SEM), energy dispersive (EDS) and X-ray photoelectron (XPS) spectroscopies show that wear scar surfaces are oxidized to Al₂O₃ and wear debris contain aluminium and iron (for L102) fluorides. For L-P106, the steel surface is covered with a P-containing tribolayer. A change of anion (L-T102; L-To102) reduces friction and wear, but the lowest values are obtained by increasing the alkyl chain length (L106; L108). When the more reactive L102 and L-P106 are used as 1 wt.% base oil additives at 25 °C, tribocorrosion processes are not observed and a friction reduction (69–75% for 1 wt.% L102) and a change from severe (10⁻³ mm³ m⁻¹) to mild wear (10⁻⁴ to 10⁻⁶ mm³ m⁻¹) is obtained with respect to the neat IL. 1 wt.% IL additives also show good lubricating performance at 100 °C.     

Spray pyrolysed Mn:Co3O4 thin film electrodes via non-aqueous route and their electrochemical parameter measurements

Present work explains the preparation of manganese incorporated cobalt oxide thin film electrodes on stainless steel by spray pyrolysis technique, via non-aqueous (methanolic) media. Structural, morphological and electrochemical characterizations of the prepared samples were made by means of XRD, SEM and electrochemical measurements. Structural elucidation confirms Co₃O₄ has face centred cubic and Mn₃O₄ has tetragonal body centred cubic structure with polycrystalline nature. Surface morphological observation shows the continuous semi porous film growth with spherical grains. Cyclic voltammetry reveals the mixed capacitive behaviour with maximum specific capacitance 605.35 F/g at the scan rate 1 mV/s in 1 M KOH electrolyte. Chronopotentiometric measurement gives energy density 33.5 Wh/kg, power density 2 kW/kg and Columbic efficiency 99.23%. Electrochemical impedance study was carried out in the frequency range 1 mHz to 1 MHz to see the internal resistance. Randles equivalent circuit was developed by using ZsimpWin software to search the circuitry parameters associated with the cell.     

Corrosion measurement of Sn–Zn lead-free solders in 6 M KOH solution

The corrosion measurements of Sn–Zn alloys with varying Zn contents from 0 wt.% to 12 wt.% were investigated in a 6 M KOH solution. The corrosion parameters of this series of materials, which include open circuit potential, galvanic corrosion current, corrosion potential, and corrosion current, were studied. The Sn–Zn alloys initially revealed an activity similar with that of pure Zn in this 6 M KOH solution. The alloy activity became more inert when the corrosion analysis was prolonged. In addition, phase and morphological analyses results confirmed the formation of mixed corrosion products on the surface after polarisation.