Green Microwave-Assisted Cladding: Enhancing SS-304 with Ni-ZrB2 Composite Coatings

Abstract

This study focuses on achieving effective deposition of a Ni and 15% ZrB2 particle mixture onto SS-304 substrate surfaces through meticulous preparation steps. Thorough cleaning of the SS-304 substrate using alcohol in an ultrasonic bath eliminated contaminants, ensuring optimal adhesion. Simultaneously, the Ni-ZrB2 mixture underwent preheating at 1200°C for 20 hours in a muffle furnace to eliminate moisture content, crucial for preventing coating defects. Uniform distribution of the preheated powder onto the substrate was crucial for consistent coating thickness. Microwave hybrid heating (MHH) using charcoal as a susceptor material overcame microwave reflection by rapidly heating the powder mixture. SEM analysis revealed a uniform dispersion of both Ni and ZrB2 particles across the substrate surface, indicating successful deposition and optimal adhesion. The cladding resulted in a significant improvement in surface hardness, with an increase of approximately 42.43%. The wear rate, measured at 0.00178 mm³/m, and the coefficient of friction, determined to be 0.246, provided crucial insights into the surface’s wear resistance and frictional behavior, confirming its suitability for applications requiring enhanced durability and performance. These findings highlight the efficacy of the microwave-assisted cladding process in enhancing SS-304 with Ni-ZrB2 composite coatings, paving the way for its utilization in various industrial applications.