The study of the structure and properties of a wear-resistant gas-thermal coating containing tungsten

Abstract

The paper presents the results of reverse engineering including metallographic, mechanical, and engineering-technical studies of used rods of a compressor produced by the Dresser-Rand company (Siemens, Germany). The study established that the original product is made of AISI 4140 steel with a working coating based on tungsten carbide applied to a depth of 0.2 mm by the HVOF method. The paper contains the results of the development of an import-substituting technological process for producing a wear-resistant powder coating of the Ni–Cr–B–WC system applied by cold gas flame spraying on the surface of a critical unit of compressor equipment in the oil and gas industry. Microanalysis identified that the sprayed spherical WC particles are evenly distributed in the nickel bond without the formation of free cavities at the lamella boundary, retain the size identical to the original powder composition upon the high-speed collision with the substrate, and minimize the level of residual mechanical stresses in the surface layer. The study shows that the sprayed coating has a high microhardness (the bases – 700 HV0.1, WC – up to 2000 HV0.1), which ensures high wear resistance during operation of the rod in a friction pair. A comparative analysis of the tribological properties of the coatings showed that when changing the shape, particle size distribution, and percentage ratio of tungsten carbide from 20 to 70 % in the nickel matrix, the overall wear resistance of the coating equivalently increases. The authors concluded on the possibility of manufacturing an import-substituting product using the gas flame spraying technology with metallurgical powder compositions containing tungsten. The authors developed an industrial technology for applying a wear-resistant coating on the working surface of a rod made of AISI 4140 steel. The paper presents the results of the analysis of the stress state of a material with a coating produced using the developed technology in comparison with the original product. In the product obtained by the experimental technology, in the process of applying the coating and its subsequent mechanical processing, uniform residual mechanical stresses are formed that do not exceed the value of the difference in the principal mechanical stresses. The paper presents the results of the study obtained both on standard samples and on a pilot part.