Abstract
Fe-based alloy coating was laser cladded on gray cast iron using Ni-Cu alloy as an intermediate layer. The cross section of the laser cladded coating was characterized by optical microscopy (OM), scanning electron microscopy (SEM) equipped with energy dispersive spectrometry (EDS), X-ray diffraction (XRD), and a Vickers hardness tester. A microdimple texture was created by reciprocating an electrolyte jet with prefabricated mask (REJP) machining on an Fe-based alloy coating. The tribological performances of untextured and textured coatings were examined through interrupted wear tests using an in-house developed reciprocating ball-on-plate tribotester under dry sliding and starved lubricated conditions. The results show that the presence of microdimple edges in the nonconformal contact region has a detrimental effect on the friction performance under dry sliding. However, the microdimples can be beneficial for trapping debris to preserve a smoother contacting surface and thus a lower volume wear track compared to untextured coatings. Due to its role in oil reservoirs and debris entrapment, the microdimple textured coating can maintain a low friction coefficient for a long time period after lubricant oil cutoff and results in a lower volume wear track under starved lubrication.Graphical abstract
Highlights
Due to its merits, such as good thermal conductivity, mechanical properties and excellent tribological behavior [1], gray cast iron is widely used for manufacturing hydraulic/pneumatic equipment, machine tools, general industrial machines, and transportation equipment [2]
The laser cladding system consists of a semiconductor laser generator (LDF 4000–100), a six degrees of freedom industrial robot (KUKA KR30HA), a coaxial laser head with four nozzles (Precitec YC52), and a double silo negative pressure gas powder feeder (RC-PGF-D, Raycham)
The morphology and microstructure of the cross-section were examined by optical microscopy (OM, GX51, OLYMPUS, Tokyo, Japan) and scanning electron microscopy (SEM, ZEISS-SUPRA 55 SAPPHIRE, Oberkochen, Germany) equipped with energy dispersive spectrometry (EDS, Oxford Instruments, Oxford, UK)
Summary
Due to its merits, such as good thermal conductivity, mechanical properties and excellent tribological behavior [1], gray cast iron is widely used for manufacturing hydraulic/pneumatic equipment, machine tools, general industrial machines, and transportation equipment [2]. Owing to the high carbon content of gray cast iron, a large number of brittle phases, namely, chilled. The most widely used texturing techniques are laser surface texturing, microelectric discharge machining and electrochemical texturing [13]. In the present study, aiming to reduce the formation of hard and brittle phases at the interface, a Ni-Cu layer with low carbon solubility was fabricated on gray cast iron as an intermediate layer. The tribological performances of the laser cladded coating and the surface textured coating under dry sliding and starved lubrication conditions were investigated
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