SYNTHESIS AND CHARACTERIZATION OF COMPOSITE COATING FOR WEAR RESISTANCE APPLICATION

Abstract

Degradation of the material because of wear and corrosion pose great challenges for the multiple industrial environments, forcing the researchers for the advance solution to enhance the life and applicability of the materials. To solve these problems, ultra-high temperature composite coatings have emerged as prominent solutions due to their property to mitigate the corrosion and wear of industrial materials. In the current investigation of composite coating for wear resistance, friction, and corrosion applications at elevated temperature, two ultra-high temperatures composite coatings (ZrB2-SiC & NiCr-Mo-WC) have been synthesised with Thermal Spray Techniques. The coatings have been developed with the constant process parameters of the machines. A set of characterisation techniques with scanning electron microscope (SEM), X-ray diffraction (XRD), energy dispersive X-ray spectroscopy (EDS), is used to investigate the morphological attributes of the developed coatings, elemental distribution, and crystalline configuration. Mechanical and tribological properties have been studied with help of Vickers Micro-hardness tester, Pin-on-Disc Tribometer and Pulstec make residual stress analyser. Post hot corrosion test of the developed coating have also been analysed. Investigation outcomes from the current study showed the exceptional wear and corrosion resistance efficiency of the developed ZrB2-SiC and NiCr-Mo-SiC composite coatings system, surpassing the efficiencies of the traditional coatings. The thickness of the ZrB2-SiC coating was 300-400µm, Value of the (COF) coefficient of friction ranged from 0.57 to 0.7 and wear rate of the coating (2.02 x 10-3mm3 /Nm) was lower than the substrate material (2.8 x 10-3 mm3 /Nm). ZrO2 was formed as protective layer during the corrosion test against the molten sulphate/vanadate salt penetration. This coating has enormous potential to work as corrosion resistant for hypersonic applications. The hardness of the Mo-NiCr-Mo-W composite coating increased notably with the upsurge of temperature with the rise of temperature reaching at the value of 290.8V at 400oC. Residual stress decreased with the increase of temperature with highest value of 354 MPa at 100oC.The COF shows it maximum value at 400oC Degradation of the material because of wear and corrosion pose great challenges for the multiple industrial environments, forcing the researchers for the advance solution to enhance the life and applicability of the materials. To solve these problems, ultra-high temperature composite coatings have emerged as prominent solutions due to their property to mitigate the corrosion and wear of industrial materials. In the current investigation of composite coating for wear resistance, friction, and corrosion applications at elevated temperature, two ultra-high temperatures composite coatings (ZrB2-SiC & NiCr-Mo-WC) have been synthesised with Thermal Spray Techniques. The coatings have been developed with the constant process parameters of the machines. A set of characterisation techniques with scanning electron microscope (SEM), X-ray diffraction (XRD), energy dispersive X-ray spectroscopy (EDS), is used to investigate the morphological attributes of the developed coatings, elemental distribution, and crystalline configuration. Mechanical and tribological properties have been studied with help of Vickers Micro-hardness tester, Pin-on-Disc Tribometer and Pulstec make residual stress analyser. Post hot corrosion test of the developed coating have also been analysed. Investigation outcomes from the current study showed the exceptional wear and corrosion resistance efficiency of the developed ZrB2-SiC and NiCr-Mo-SiC composite coatings system, surpassing the efficiencies of the traditional coatings. The thickness of the ZrB2-SiC coating was 300-400µm, Value of the (COF) coefficient of friction ranged from 0.57 to 0.7 and wear rate of the coating (2.02 x 10-3mm3 /Nm) was lower than the substrate material (2.8 x 10-3 mm3 /Nm). ZrO2 was formed as protective layer during the corrosion test against the molten sulphate/vanadate salt penetration. This coating has enormous potential to work as corrosion resistant for hypersonic applications. The hardness of the Mo-NiCr-Mo-W composite coating increased notably with the upsurge of temperature with the rise of temperature reaching at the value of 290.8V at 400oC. Residual stress decreased with the increase of temperature with highest value of 354 MPa at 100oC.The COF shows it maximum value at 400oC and minimum at 100oC while wear rate was maximum at 100oC. SEM analysis shows that erosion, abrasion, worn surface and layer delamination as prominent wear mechanisms. and minimum at 100oC while wear rate was maximum at 100oC. SEM analysis shows that erosion, abrasion, worn surface and layer delamination as prominent wear mechanisms.