Abstract
The present experimental work reveals the surface characteristics like wettability, thermal and sliding wear behaviour of plasma-sprayed red mud (RM) coatings premixed with fly ash (FA). Varying weight % of FA (10, 20, 30 and 40)—RM composite powder is used as precursor for coating. Atmospheric plasma-sprayed coatings are developed at different operating power like 5 kW, 10 kW, 15 kW and 20 kW separately on mild steel substrate. Tribological behaviour viz. sliding wear properties are studied at distinct operating load (10N, 15N, 20N, 25N), speed (40 rpm, 50 rpm, 60 rpm, 70 rpm) and track diameter of 100 mm using a pin on disc tribometer for duration of 30 minutes with 3 minute gap period for each experiment. The DSC and TGA experiments of the coatings are performed to understand the high temperature application areas. The contact angle result signifies the wettability of the prepared coatings is principally a function of composition. The reaction of surface roughness and spraying power is in-significant on water contact angle (WCA). In conclusion, the sliding wear experiments are optimized by Taguchi method to ascertain the influencing parameter on wear.
Highlights
The water contact angle (WCA) is maximum for 10% fly ash (FA) content coating
Hydrophilicity increases with FA content of the formulated coatings
The water attracting property of the coatings is attributing to high amount of silica (SiO2) content in fly ash
Summary
Plasma Spray Technology (PST) has been widely used in industrial practises for its versatility like high deposition rate, capacity to coat complex shapes, and abil-. Depending on water contact angle (WCA), the surface of all the materials and coatings is divided into hydrophobic or hydrophilic. The surface models for wetting on rough surfaces are governed by either Wenzel or Cassie-Baxter state [9] [10]. Cassie and Baxter model is applicable and headed by Equation (3). Thermal behaviour of red mud composite coatings at elevated temperature on mild steel is presented [29]. An attempt has been made to evaluate the wettability of plasma-sprayed red mud-fly ash composite coatings with respect to water. Design of experiments (DOE) is conducted to check the effect of operating parameters on wear
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