Abstract
. Creating a functionally oriented, including nanostructured, anti-friction materials and coatings with qualitatively new complex of service properties is an important scientific and practical problem. In particular, for the cable industry it is urgent task of ensuring the high performance properties of fast deteriorating stretching and supporting rollers. Working surfaces of these parts operate under practically dry friction conditions with constantly updated material of stretching wire. Plasma spraying is one of the widely used methods of surface engineering to create wear resistant coatings and which is characterized with process flexibility and the ability to create coatings using various materials and alloys including composite ones. The installation UPU-3D with the PP-25 plasma torch was used for plasma spraying. The thickness of the sprayed layer was 0.8–1.1 mm. As a material for the deposition of composite coatings a powder mixture of self-fluxing nickel alloy PG-HN80SR4 (system Ni–Fe–Cr–Si–B–C) and a neutral oxide ceramics Al 2 O 3 was used. The amount of ceramics varied from 15 to 33 %. This ceramic oxide was selected due to the desire to reduce coatings’ costs while providing high durability. Carried out phase and microstructural studies have shown when ceramics was added in an amount more than 20 % a formation of conglomerates formed by not melted alumina particles often was observed. These conglomerates serve as crack formation centers in the coating. The phase composition of the coatings practically does not depend on the content of ceramics compounds. Tribological tests have shown that the best results were obtained when the content of the oxide ceramic in the coating was in the range from 15 to 20 %.
Highlights
In modern mechanical engineering scientific and applied studies in the field of developing functionally oriented, including nanostructured, antifriction materials and coatings with qualitatively new service complex of properties are intensively carried out
Analysis of the microstructures showed that all coatings, regardless of the Al2O3 concentration, had a similar structure: base – Nickel eutectic with distributed fine particles of chromium compounds and rather big particles of aluminium oxide, often having a lamellar form
The best combination of the tribological properties was obtained for coating with 15 % of oxide ceramics (Fig. 5, 6)
Summary
In modern mechanical engineering scientific and applied studies in the field of developing functionally oriented, including nanostructured, antifriction materials and coatings with qualitatively new service complex of properties are intensively carried out. This is especially true for new technical applications. Depending on the technological methods and processing modes, different kinds of surface properties, such as optical properties and mechanical properties can be locally improved while maintaining the properties such as the strength of the base material The application of these developments in friction pairs can significantly expand the range of operation modes, load capacity and service life of friction units [1]. Advantages of this process are flexibility and possibility to deposit different materials including ceramics onto surface of substrate [2]
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