Mathematical modelling and validation of the mechanical properties of HVOF-sprayed WC-12Co coatings considering the phase composition and defects generated at different process parameters

IF 5.3 2区 材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS Surface & Coatings Technology Pub Date : 2024-10-05 DOI:10.1016/j.surfcoat.2024.131433
Subham Sarkar, Rajib Das, Partha Pratim Bandyopadhyay
{"title":"Mathematical modelling and validation of the mechanical properties of HVOF-sprayed WC-12Co coatings considering the phase composition and defects generated at different process parameters","authors":"Subham Sarkar,&nbsp;Rajib Das,&nbsp;Partha Pratim Bandyopadhyay","doi":"10.1016/j.surfcoat.2024.131433","DOIUrl":null,"url":null,"abstract":"<div><div>The thermal spraying process involves many machine-based parameters or independent variables (fuel flow rate, oxygen flow rate, powder feed rate, stand-off distance and many others in the HVOF process). Any combination of these parameters produces only two measurable responses, namely, particle temperature and particle velocity. In this current work, first, the machine-based spray parameters are varied in specific ways to produce different particle temperatures at near-constant velocities and vice-versa. This approach has reduced the number of independent variables to only two. These two factors further influence the in-flight particle reactions, thereby affecting the phase composition and the microstructural defects in the as-sprayed coatings. The X-ray diffraction patterns of the as-sprayed coatings revealed the presence of W<sub>2</sub>C, W, Co<sub>3</sub>W<sub>9</sub>C<sub>4</sub>, and amorphous <em>Co</em>-W-C phases apart from the WC phase. The W<sub>2</sub>C and W originated owing to the decarburization of the WC phase. On the other hand, the dissolution of the carbide in molten binder led to the formation of Co<sub>3</sub>W<sub>9</sub>C<sub>4</sub> and the amorphous <em>Co</em>-W-C phase. The nano-hardness of both the carbide and binder phases increased with an increase in particle temperature owing to a higher degree of decarburization and carbide dissolution respectively. The porosity was the most significant micro-structural defect present in the as-sprayed coatings. An increase in either particle temperature or velocity reduced the porosity present in the as-sprayed coatings. The mechanical properties (microhardness, elastic modulus and indentation fracture toughness) tend to improve as porosity decreases. A comprehensive mathematical model is proposed to predict the mechanical properties of as-sprayed coatings as a function of composition and defects. Finally, the process maps of mechanical properties were plotted in temperature-velocity space.</div></div>","PeriodicalId":22009,"journal":{"name":"Surface & Coatings Technology","volume":"494 ","pages":"Article 131433"},"PeriodicalIF":5.3000,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Surface & Coatings Technology","FirstCategoryId":"88","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0257897224010648","RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"MATERIALS SCIENCE, COATINGS & FILMS","Score":null,"Total":0}
引用次数: 0

Abstract

The thermal spraying process involves many machine-based parameters or independent variables (fuel flow rate, oxygen flow rate, powder feed rate, stand-off distance and many others in the HVOF process). Any combination of these parameters produces only two measurable responses, namely, particle temperature and particle velocity. In this current work, first, the machine-based spray parameters are varied in specific ways to produce different particle temperatures at near-constant velocities and vice-versa. This approach has reduced the number of independent variables to only two. These two factors further influence the in-flight particle reactions, thereby affecting the phase composition and the microstructural defects in the as-sprayed coatings. The X-ray diffraction patterns of the as-sprayed coatings revealed the presence of W2C, W, Co3W9C4, and amorphous Co-W-C phases apart from the WC phase. The W2C and W originated owing to the decarburization of the WC phase. On the other hand, the dissolution of the carbide in molten binder led to the formation of Co3W9C4 and the amorphous Co-W-C phase. The nano-hardness of both the carbide and binder phases increased with an increase in particle temperature owing to a higher degree of decarburization and carbide dissolution respectively. The porosity was the most significant micro-structural defect present in the as-sprayed coatings. An increase in either particle temperature or velocity reduced the porosity present in the as-sprayed coatings. The mechanical properties (microhardness, elastic modulus and indentation fracture toughness) tend to improve as porosity decreases. A comprehensive mathematical model is proposed to predict the mechanical properties of as-sprayed coatings as a function of composition and defects. Finally, the process maps of mechanical properties were plotted in temperature-velocity space.
查看原文
分享 分享
微信好友 朋友圈 QQ好友 复制链接
本刊更多论文
考虑到相组成和不同工艺参数下产生的缺陷,对 HVOF 喷射 WC-12Co 涂层的机械性能进行数学建模和验证
热喷涂工艺涉及许多基于机器的参数或自变量(HVOF 工艺中的燃料流速、氧气流速、粉末进给率、间距和许多其他参数)。这些参数的任何组合都只会产生两个可测量的响应,即颗粒温度和颗粒速度。在目前的工作中,首先以特定方式改变基于机器的喷雾参数,从而在速度接近恒定的情况下产生不同的颗粒温度,反之亦然。这种方法将自变量的数量减少到只有两个。这两个因素会进一步影响飞行中的粒子反应,从而影响喷涂涂层中的相组成和微观结构缺陷。喷涂涂层的 X 射线衍射图样显示,除 WC 相外,还存在 W2C、W、Co3W9C4 和无定形 Co-W-C 相。W2C 和 W 源自 WC 相的脱碳。另一方面,碳化物在熔融粘结剂中的溶解导致了 Co3W9C4 和无定形 Co-W-C 相的形成。随着颗粒温度的升高,碳化物相和粘结剂相的纳米硬度都会增加,这分别是由于脱碳和碳化物溶解的程度提高了。孔隙率是喷涂涂层中最显著的微观结构缺陷。颗粒温度或速度的增加都会降低喷涂涂层中的孔隙率。随着孔隙率的降低,机械性能(显微硬度、弹性模量和压痕断裂韧性)趋于改善。我们提出了一个综合数学模型,用于预测作为成分和缺陷函数的喷涂涂层的机械性能。最后,在温度-速度空间绘制了机械性能过程图。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
求助全文
约1分钟内获得全文 去求助
来源期刊
Surface & Coatings Technology
Surface & Coatings Technology 工程技术-材料科学:膜
CiteScore
10.00
自引率
11.10%
发文量
921
审稿时长
19 days
期刊介绍: Surface and Coatings Technology is an international archival journal publishing scientific papers on significant developments in surface and interface engineering to modify and improve the surface properties of materials for protection in demanding contact conditions or aggressive environments, or for enhanced functional performance. Contributions range from original scientific articles concerned with fundamental and applied aspects of research or direct applications of metallic, inorganic, organic and composite coatings, to invited reviews of current technology in specific areas. Papers submitted to this journal are expected to be in line with the following aspects in processes, and properties/performance: A. Processes: Physical and chemical vapour deposition techniques, thermal and plasma spraying, surface modification by directed energy techniques such as ion, electron and laser beams, thermo-chemical treatment, wet chemical and electrochemical processes such as plating, sol-gel coating, anodization, plasma electrolytic oxidation, etc., but excluding painting. B. Properties/performance: friction performance, wear resistance (e.g., abrasion, erosion, fretting, etc), corrosion and oxidation resistance, thermal protection, diffusion resistance, hydrophilicity/hydrophobicity, and properties relevant to smart materials behaviour and enhanced multifunctional performance for environmental, energy and medical applications, but excluding device aspects.
期刊最新文献
Study on a facile method of in-situ fabricating enhanced corrosion protection LDH/PEO composites coating on Mg alloy and its growth behavior Editorial Board Damage research of supersonic plasma sprayed Al2O3/PF composite coatings on resin matrix surfaces under thermally coupled operating conditions Experimental study on thermal cycle performance of DD6 single crystal thermal barrier coating with film cooling holes Synthesis of 2D multilayer molybdenum disulfide and graphene using a rapid thermal annealing system
×
引用
GB/T 7714-2015
复制
MLA
复制
APA
复制
导出至
BibTeX EndNote RefMan NoteFirst NoteExpress
×
×
提示
您的信息不完整,为了账户安全,请先补充。
现在去补充
×
提示
您因"违规操作"
具体请查看互助需知
我知道了
×
提示
现在去查看 取消
×
提示
确定
0
微信
客服QQ
Book学术公众号 扫码关注我们
反馈
×
意见反馈
请填写您的意见或建议
请填写您的手机或邮箱
已复制链接
已复制链接
快去分享给好友吧!
我知道了
×
扫码分享
扫码分享
Book学术官方微信
Book学术文献互助
Book学术文献互助群
群 号:481959085
Book学术
文献互助 智能选刊 最新文献 互助须知 联系我们:info@booksci.cn
Book学术提供免费学术资源搜索服务,方便国内外学者检索中英文文献。致力于提供最便捷和优质的服务体验。
Copyright © 2023 Book学术 All rights reserved.
ghs 京公网安备 11010802042870号 京ICP备2023020795号-1