Abstract
The paper investigates the cavitation erosion (CE) and sliding wear (SW) resistance of cold-sprayed Al/Al2O3 and Cu/Al2O3 composites and studies them in relation to a set of metallic materials such as aluminium alloy (AlCu4Mg1), pure copper (Cu110), brass (CuZn40Pb2) and stainless steel (AISI 304). The coatings were deposited on stainless steel by low-pressure cold spray (LPCS) using Al (40 wt.%) and Cu (50 wt.%) blended with Al2O3 (60 and 50 wt.%, respectively) feedstocks. CE resistance was estimated by the stationary sample method according to the ASTM G32 standard. The SW test was conducted using a ball-on-disc tester with compliance to the ASTM G99 standard. Results obtained for the LPCS coatings show that the Cu/Al2O3 coating exhibits a denser structure but lower adhesion and microhardness than Al/Al2O3. The Al/Al2O3 and Cu/Al2O3 resistance to cavitation is lower than for bulk alloys; however, composites present higher sliding wear resistance to that of AlCu4Mg1, CuZn40Pb2 and stainless steel. The CE wear mechanisms of LPCS composites start at the structural discontinuities and non-uniformities. The cavitation erosion degradation mechanism of Al/Al2O3 relies on chunk material detachment while that of Cu/Al2O3 initiates by alumina removal and continues as layer-like Cu-metallic material removal. CE damage of metal alloys relies on the fatigue-induced removal of deformed material. The SW mechanism of bulk alloys has a dominant adhesive mode. The addition of Al2O3 successfully reduces the material loss of LPCS composites but increases the friction coefficient. Coatings’ wear mechanism has an adhesive-abrasive mode. In both CE and SW environment, the behaviour of the cold-sprayed Cu/Al2O3 composite is much more promising than that of the Al/Al2O3.
Highlights
Abrasion, erosion and sliding cause failure in various applications, e.g., in oil and gas, offshore or mining industries
The rough top surfaces of the as-deposited coatings are characterized by wavy morphology corresponding to passes of the cold spray gun, which is typical of the Cold spray (CS) technology [64]
According to Chen [36], when spraying the blends of Cu/Al2 O3, the addition of alumina can result in a mechanical hammering effect of the alumina particles, which is promising for the elimination of pure copper porosity
Summary
Erosion and sliding cause failure in various applications, e.g., in oil and gas, offshore or mining industries. Abrasion and erosion appear due to wear by abrasive particles or by the impact and entrainment of hard-faced particles in a transport fluid. Sliding wear (SW) is an effect of motion of two moving bodies with different relative velocity magnitudes and/or directions. The liquid itself can induce material degradation in the form of liquid impingement erosion, cavitation erosion (CE) or corrosion [1,2,3,4]. Metallic materials used in the marine, power and food environments are susceptible to corrosion, erosion or CE damage [5,6,7,8]. In most engineering applications abrasion, i.e., sliding wear
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
