Effect of abrasive particle sizes on abrasive wear of ceramic coatings sprayed by plasma process

Abstract

This study examines the effects of abrasive grain size on abrasive wear behaviors on surfaces coated with different types of ceramics. To this end, the surface of AISI 1040 steel is coated with the ceramic materials of 5% SiO2–3% TiO2–92% Cr2O3, 60% Al2O3–40% TiO2, pure Al2O3 and 87% Al2O3–13% TiO2 using the plasma method. Following the coating process, the abrasive wear resistance of each sample is tested by the ring-on-disc method. 80–220 mesh SiC abrasive paper is used as abrasive. The best wear resistance is obtained with the ceramic coating containing 92% Cr2O3, which is followed by pure Al2O3 and 87% Al2O3–13% TiO2, respectively. The lowest wear resistance is observed in 60% Al2O3–40% TiO2 ceramic coating. Wear resistance of the samples increases with increasing hardness value and decreasing abrasive grain size. It is observed that wear mechanisms occurring on the samples’ wear surfaces change with changing abrasive grain size. Wear mechanisms such as microscratching, microcracking, and plastic deformation are observed in the samples.