Coating properties, energy consumption, and cost analysis of the induction cladding process

Abstract

Induction cladding may provide an innovative approach for repairing or remanufacturing grey cast iron components. A complete analysis of the induction cladding technology is important for promoting practical applications. Three commonly used alloy powders were chosen for the research, and the induction cladding technology was thoroughly investigated from three aspects: the coating properties, energy consumption, and unit cost. The porosity, microhardness, and frictional performance were defined as the coating properties. An energy consumption measurement system was set up to quantitatively assess the energy consumption during the induction cladding process. Finally, the unit costs of alloy powders used for the induction cladding were assessed. The results suggest that the Ni-based coating possesses the best coating properties except for a porosity that is relatively high (but still lower than that of coatings fabricated using other surface coating technologies). The microhardness values of Ni-based and Fe-based coatings are higher than that of the Co-based coating, and the Ni-based coating has the lowest coefficient of friction and smallest wear volume. The energy consumptions per unit coating of the three alloy powders are similar, although that of the Fe-based coating is slightly lower. The unit cost of the Co-based alloy powder is approximately three times higher than that of Ni-based and Fe-based alloy powders. Therefore, based on comprehensive assessment, the Ni-based alloy coating shows the best performance.