Abstract
To increase the lifetime of metallic molds and protect their surface from wear, a fluorinated ethylene propylene (FEP) polymer was coated onto a stainless-steel (SS304) substrate, using an air spray process followed by a heat treatment. The microstructural properties of the coating were studied using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) as well as X-ray diffraction. The mechanical properties and adhesion behavior were analyzed via a nanoindentation test and progressive scratching. According to the results, the FEP coating had a smooth and dense microstructure. The mechanical properties of the coatings, i.e., the hardness and Young’s modulus, were 57 ± 2.35 and 1.56 ± 0.07 GPa, respectively. During scratching, successive delamination stages (initiation, expansion, and propagation) were noticed, and the measured critical loads LC1 (3.36 N), LC2 (6.2 N), and LC3 (7.6 N) indicated a high adhesion of the FEP coating to SS304. The detailed wear behavior and related damage mechanisms of the FEP coating were investigated employing a multi-pass scratch test and SEM in various sliding conditions. It was found that the wear volume increased with an increase in applied load and sliding velocity. Moreover, the FEP coating revealed a low friction coefficient (around 0.13) and a low wear coefficient (3.1 × 10−4 mm3 N m−1). The investigation of the damage mechanisms of the FEP coating showed a viscoelastic plastic deformation related to FEP ductility. Finally, the coating’s resistance to corrosion was examined using electrochemical measurements in a 3.5 wt% NaCl solution. The coating was found to provide satisfactory corrosion protection to the SS304 substrate, as no corrosion was observed after 60 days of immersion.
Highlights
Stainless steel is widely use in the fabrication of molds elements using in the chemical and food processing industry, in metal forming and pharmaceutical molds [1,2,3,4]
From the topview scanning electron microscopy (SEM) micrographs (Figure 2a), it can be observed that the fluorinated ethylene propylene (FEP) coatings had a dense, poreless, and homogeneous structure
A protective FEP coating was deposited on a stainless-steel substrate using the air spray process and cured to obtain a compact and uniform film
Summary
Stainless steel is widely use in the fabrication of molds elements using in the chemical and food processing industry, in metal forming and pharmaceutical molds [1,2,3,4]. In the strongly aggressive media containing chloride anions, stainless steels lack corrosion resistance [6,7]. These failure mechanisms directly involve the molds’ surface, creating a serious problem in the manufacturing of casting, and shortens molds’ life [8,9]. To solve this problem, which causes additional costs for mold reconditioning and reduced productivity, various metallic, ceramic, and polymeric coatings have been proposed. In our previous work [10], polymeric perfluoroalkoxy coatings were used to protect agri-food molds to prevent corrosion and wear
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