Abstract
In the current study, electrolytic deposition using two different electrodes, copper (Cu) and nickel (Ni) was investigated with the aim of protecting the worn surface during mechanical sectioning and polishing, for a posterior examination of the sub-surface microstructure. The efficacies of the two coatings were visually assessed based on its adhesivity and the ability to protect the wear tracks of an as-cast 26% Cr high chromium cast iron (HCCI) alloy. It was observed that electrodeposition using Cu as the electrode was ineffective owing to a poor adhesivity of the coating on the HCCI surface. The coating had peeled off at several regions across the cross-section during the mechanical sectioning. On the other hand, Ni electroplating using Ni strike as the electrolyte was successfully able to protect the wear track, and the sub-surface characteristics of the wear track could be clearly visualized. A uniform coating thickness of about 8 µm was deposited after 30–40 min with the current density maintained between 1 and 5 A/dm2. The presence of the Ni coating also acted as a protective barrier preventing the ejection of the broken carbide fragments underneath the wear track.
Highlights
A quarter of the world’s energy produced is spent in overcoming issues related to tribology [1]
The failures associated with friction and wear in the mining and mineral sector alone constitute for about 6% of the annual global energy consumption [2]
Electrolytic deposition was carried out on the worn surface of an as-cast high chromium cast iron (HCCI) alloy to prevent any unwanted microstructural modifications during the mechanical sectioning and polishing, in order to examine the microstructure of the sub-surface
Summary
A quarter of the world’s energy produced is spent in overcoming issues related to tribology [1]. To mitigate the monetary and energy loss encountered during the operation, researchers are constantly seeking to understand the wear mechanisms and subsequently, improve the material in use [3, 4]. In addition to employing new materials apt for wear-related applications, existing materials can be microstructurally modified, or coated with a suitably wear resistant material. HCCIs are alloys containing a dispersion of hard M7C3 (M: Cr, Fe) type carbides in a supportive, modifiable matrix (austenite, martensite, ferrite), enabling it to be used in a wide variety of applications in the mining and mineral sector, such as ball mill liners, pulverizing equipment, feeders, etc. A thorough characterization of the worn surface is imperative for understanding the ensuing wear mechanisms aiding in the subsequent development of better wear resistant materials. In the specific case of HCCIs, the overall wear behaviour is a synergistic contribution between the hard carbide and the matrix that surrounds it [3, 11]
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