Abstract
Plasma cladding coupled induction heating was developed and successfully used to fabricate Ni60A coating on the surface of copper pipe. By matching the swing arc with the rotating copper pipe, the cladding efficiency was as high as 32.72 mm2/s. From the head to the tail of the coating, the wear resistance changed from 4.5 to 1.8 times that of pure copper. During the cladding process with constant current, the surface temperature of the cladding zone and the bath depth gradually increased. The corresponding dilution ratio increased, accompanied by the widening of the interface transition zone and the growth of precipitated phases (CrB and Cr23C6). Due to the gradient change of composition, the coating can be regarded as an in situ synthesized gradient coating. The critical point of sudden change of temperature in cladding zone was 850 °C, at which point the wear mechanism changed from abrasive wear to adhesive wear. The proper surface temperature of cladding zone should be controlled within 600–850 °C, which can be achieved by matching the cladding current and induction heating power. Results indicated that plasma cladding coupled induction heating is a potentially effective method to prepare high-quality coating on the surface of a large-complex-curved copper component.
Highlights
Steel is the most widely used metal material in the world [1,2,3]
The material used for making tuyere small sleeve is pure copper, which has high thermal conductivity
Among the surface engineering technologies, plasma cladding has the unique advantages of low cost and high efficiency, which results in a different coating with metallurgical bonding and high performance on a copper substrate
Summary
Steel is the most widely used metal material in the world [1,2,3]. At present, more than 75% of steel is produced from iron ore by the blast furnace-converter long process. It is necessary to fabricate a wear-resistant coating on the surface of the copper sleeves to prolong their service life. The surface coating technologies including electroplating, cold spraying, thermal spraying, laser cladding and plasma cladding are used to improve the wear resistance of copper [10,11,12,13,14]. Among the surface engineering technologies, plasma cladding has the unique advantages of low cost and high efficiency, which results in a different coating with metallurgical bonding and high performance on a copper substrate. Li et al [15] prepared the Ni-based (Ni25) wear-resistant layer by plasma cladding after preheating the copper plate. Ke et al [16] successfully prepared Ni60 coating on the surface of copper plate by using plasma cladding. Tpaobwlede1rshwoaws sutsheedcahsemclaicdadlicnogmmpoatseitriioanl, wofhtihche Nhai6s0Aa pgowoddecro. mTphaetpiboilwitdyerwiisthspchoeprpicearl w[2i0th–2a2]s.izTeaobfle451–1s0h0owμms t(hFeiguchreemS2icianl
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