H13 Steel Substrates Research Articles

Microstructure Evolution and Wear Behavior of Stellite12 Coating Prepared by Laser-Directed Energy Deposition on H13 Steel

Laser-directed energy deposition (LDED) was employed to apply a Stellite12 coating onto an H13 steel substrate. This study explored the effects of processing parameters on the dimensions of the deposited tracks. Comprehensive examinations were conducted on the coatings to assess their phase composition, microstructure, and wear resistance properties. The relationship between microstructural characteristics and thermal field was investigated through a synergy of numerical simulations and experimental analyses. The findings revealed that the Stellite12 coating displayed a heterogeneous microstructure with epitaxial growth and a slight texture across successive layers. The primary phase comprised a γ-Co solid solution and M23C6 carbides, contributing to a significant enhancement in hardness, which was observed to be 2.2 times higher than that of the substrate. The coating demonstrated superior performance in terms of lower friction coefficients and reduced wear rates at both room and elevated temperatures. The predominant wear mechanisms identified were oxidative wear. These results underscore the promising applications of Stellite12 coatings in industrial contexts facilitated by LDED technology.

Oxygen concentration – A governing parameter for microstructural tailoring of duplex AlCrSiON coatings for superior mechanical, tribological, and anti-corrosion performance

This study investigates the impact of increasing oxygen levels on structure, and mechanical properties and tribological performance of duplex AlCrSiON coatings. AISI H13 steel and tungsten carbide substrates are coated using arc ion plating with increasing oxygen flow rate up to 200 sccm with varying oxygen concentration. High-resolution transmission electron microscopy, scanning electron microscopy, X-ray photoelectron spectroscopy, X-ray diffraction, and three-dimensional profilometer are used to study morphological and structural evolution. Correspondingly, the coatings are assessed for hardness, adhesion strength, friction coefficient, and resistance against corrosion and wear. A 50–100 sccm oxygen flow rate is considered as an optimal range to receive lower surface roughness. Generally, the addition of oxygen has compromised hardness and friction coefficient but improve adhesion strength, wear and corrosion resistance with increasing oxygen concentration. The immersion tests have identified pitting corrosion as a dominating failure mechanism for AlCrSiON coatings when exposed to molten A380 aluminium alloy. This corrosion resistance stems from their dense microstructure, excellent thermal stability, and the presence of fcc-(Al, Cr)2O3 phase structure. This study demonstrates that controlled oxygen concentration is a crucial parameter for tuning the microstructure of AlCrSiON coatings to achieve superior mechanical, tribological, and anti-corrosion performance, particularly for high-pressure die-casting applications.

Influence of Ti–V content on (CrAlTiV)N coating: Structure and corrosion response

(CrAlTiV)N coatings were deposited by DC magnetron sputtering on AISI H13 steel substrates at various Ti–V contents. The microstructural evolution, chemical composition and phases of coatings, were studied systematically by scanning, atomic force and transmission microscopies, energy dispersive x-ray spectroscopy and x-ray diffraction. The corrosion response of the coatings was evaluated by electrochemical impedance spectroscopy and potentiodynamic polarization techniques. Crystalline structures of CrAlN and CrAlTiVN were developed. The morphology of pyramidal tips disappeared, increasing the densification of the coatings and decreasing their roughness and the grain size as their amount of Ti/V increased. An evident protection of AISI H13 steel against corrosion was presented in all coating systems, which were characterized by their dielectric behavior. The high densification, smaller grain size and the formation of the nitride phase (CrAlTiV)N contributed to this having the best corrosion performance, while the appearance of the amorphous phase VN with superconductive character of the (CrAlTiV)N-14 at% coating led to an increase in its conductivity despite its apparently compact structure.

Effect of CeO2 on the microstructure and properties of AlCoCrFeNi2.1 laser cladding coatings

In the process of strengthening the substrate’s surface properties, it is easy to produce cracks or air holes and other defects between the coatings and the substrate, and rare earth elements can improve the microstructure and properties of the metal surface coatings. Using laser cladding(LC) technology, the effect of the addition of rare earth oxides CeO2 on the properties of AlCoCrFeNi2.1 coatings is investigated to find the optimal amount of CeO2 added. AlCoCrFeNi2.1 alloy powder doped with Xwt% (X = 0–3) rare-earth oxide CeO2 was clad on the surface of the H13 steel substrate by laser cladding process using RFL-C3000 laser. The macroscopic morphology, microstructure, hardness, and corrosion resistance of specimens were analyzed and studied by optical microscope (OM), scanning electron microscope (SEM), X-ray diffractometer (XRD), hardness tester, and other equipment. The results show that the addition of the appropriate amount of rare earth oxide CeO2 (3 %) can effectively reduce the cracks, air holes, and inclusions in the composite layer, and promote grain refinement. The addition of 3 wt%CeO2 to AlCoCrFeNi2.1 can improve the microstructure uniformity and surface hardness of the coatings, and significantly improve the wear and corrosion resistance of the composite coatings.

Influence of 3-aminopropyltriethoxysilane/tetraethylorthosilicate mixture pretreatment on the microstructure and corrosion resistance of zeolite coating

ABSTRACT The influence of silane pretreatment with five different volume ratios (100/0, 75/25, 50/50, 25/75, and 0/100) of 3-aminopropyltriethoxysilane (APTES)/tetraethylorthosilicate (TEOS) on microstructure and corrosion resistance of the hydrothermal synthesized zeolite coatings on the H13 steel substrates was investigated. The surface of the zeolite coatings on the 100/0, 75/25, and 50/50 mixture of the APTES/TEOS pretreated substrates was composed of intergrown rectangular particles. Additionally, pores were observed. A 25/75 mixture of APTES/TEOS pretreatment smoothed the edges and angles of zeolite particles with gel-like materials filled in the pores. In pure TEOS pretreatment, microcracks, and much gel-like materials were observed on the zeolite coating. The electrochemical test revealed that the zeolite coating on a 50/50 mixture of the APTES/TEOS pretreated substrate exhibited the highest corrosion resistance in 3.5 wt-% NaCl solution. This was because a 50/50 mixture of APTES/TEOS pretreatment advantageously promoted development of a dense and thick gel layer, which enhanced the intergrowth of zeolite particles.

Corrosion behaviour of Tribaloy T400 coating prepared by laser cladding in molten aluminium alloys

Corrosion of molten Aluminium alloys is an important reason to lead the failure of moulds. The Tribaloy T400 coating was prepared on H13 steel by laser cladding to investigate corrosion behaviour in molten A356 Aluminium alloys at 993 K for different periods. The main phases in the Tribaloy T400 coating were primary Co-rich FCC phase and Laves phase (Co7Mo6 and Co3Mo2Si). The Tribaloy T400 coating maintain its surface integrity after immersion in molten Aluminium alloy for 7d. The corrosion resistance was improved significantly compared to H13 steel substrate. The Vickers hardness of the coating was increased from 686 to 727 HV0.3, which could be attributed to the obvious aging hardening effect in Tribaloy T400 coating.

Effect of Ti3SiC2 mass fraction on microstructure and tribological performance of laser cladded NiCr coating at high temperature

PurposeThis paper aims to investigate the effect of Ti3SiC2 on the high-temperature tribological behaviors of NiCr coating, which was beneficial to improve the friction-wear performance of hot work mold.Design/methodology/approachNiCr-Ti3SiC2 coatings were prepared on H13 steel substrate by laser cladding. The microstructure, phases and hardness of obtained coatings were analyzed using a super-depth of field microscope, X-ray diffraction and microhardness tester, respectively, and the tribological performance of obtained coatings at 500°C was investigated using a high-temperature tester.FindingsThe results show the NiCr-Ti3SiC2 coatings are comprised of γ-Ni solid, solution, TixNiy, TiC and Ti3SiC2 phases, and the coating hardness is increased with the increase of Ti3SiC2 mass fraction, which is contributed to the fine-grain and dispersion strengthening effect by the addition of Ti3SiC2. The NiCr-Ti3SiC2 coatings present excellent friction reduction and wear resistance by the synergetic action of Ti3SiC2 lubricant and hard phase, and the wear mechanism is predominated by abrasive wear and oxidation wear.Originality/valueTi3SiC2 phase was used to reinforce the tribological performance of H13 steel at high temperature, and the roles of friction reduction and wear resistance were discussed.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2023-0004/

Effect of AISI H13 Steel Substrate Nitriding on AlCrN, ZrN, TiSiN, and TiCrN Multilayer PVD Coatings Wear and Friction Behaviors at a Different Temperature Level

Moving components of industrial machines and tools are subjected to wear and friction. This reduces their useful life and efficiency in running conditions, particularly at high temperatures. One of the most popular solutions is to apply an appropriate surface coating to the tribocouple's base materials. In this study, tribometer experiments were used to evaluate the tribological performance of cathodic arc physical vapor deposited (CAPVD) AlCrN, TiSiN, CrTiN, and ZrN coatings on the gas nitrided AISI H13 tool steel to explore the effects of nitriding the steel on wear and friction behavior of these coatings at ambient and elevated temperatures. The coatings characterization is split into three main parts: mechanical, morphological, and chemical characterization. Nanoindentation has been used for mechanical characterization, thin film X-ray diffraction (XRD), and an energy-dispersive X-ray spectrometer mounted on a scanning electron microscope for chemical characterization, optical profilometer, and atomic force microscopy (AFM) for morphological characterization. Significant improvements in the adhesion qualities of the coatings to the substrate were achieved as a result of nitration. Due to this circumstance, the coatings' load-bearing capacity and high-temperature wear resistance ratings were enhanced. The wear results showed that the AISI H13 tool steel nitriding with AlCrN and ZrN layers decreased wear rates by two to three times at 700 °C.

Microstructure, chemical composition and mechanical properties of rhenium nitride hard coating deposited by reactive magnetron sputtering

Rhenium nitride coatings were deposited by reactive magnetron sputtering technique on H13 steel and polished silicon substrates. To vary the nitrogen content in the ReNx coatings, flow rates of 2, 6, and 8 sccm were used in the nitrogen line gas, while argon flow was kept constant (40 sccm). Different substrate temperatures of 100 °C, 175 °C, and 250 °C were also evaluated. A stack of four Ti/TiN bilayers with a total thickness of 200 nm was deposited, in order to improve the adhesion of the rhenium nitride top layer. X- ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM), and X- ray diffraction (XRD) analysis of the coatings confirmed the formation of ReNx compounds with a face-centered cubic (FCC) structure for all samples produced, together with the formation of rhenium oxides and metallic rhenium. The nanohardness of the coating, measured by atomic force microscopy (AFM), reached values up to 24 GPa. The coating design and hardness value obtained have not been previously reported for ReN synthesized by physical vapor deposition (PVD) and represent an important contribution to the current state of knowledge and a relevant database for future research projects on ReN.

Effect of laser remelting on corrosion and wear resistance of Fe82Cr16SiB alloy coatings fabricated by extreme high-speed laser cladding

• Micro-scale Fe82Cr16SiB coating is prepared by single-layer extreme high-speed laser cladding. • The flatness of Fe82Cr16SiB coating and structural refinement could be improved by laser remelting. • The corrosion resistance, hardness and wear resistance of Fe82Cr16SiB coating are improved by remelting treatment. With scanning speeding of 20 ∼ 200 m/min, extreme high-speed laser cladding is a high-efficiency choice to fabricate thin protective coatings with thickness of 0.01 ∼ 0.25 mm on metal parts. Laser remelting is considered as an effective strategy to improve surface characteristics. In the present paper, mirco-scale Fe82Cr16SiB alloy single-layer coatings are successfully prepared on H13 steel substrate by above integrated process with slow scanning speed below 5 m/min. The flatness of the defect-free coatings is substantially improved with the formation of a refined gradient microstructure along the growth direction. The remelted coating exhibits enhanced corrosion resistance, higher hardness, good wear resistance with lower friction coefficient.

Improvement of the wear and corrosion resistance of nitrocarburized H13 steel using hydrothermal-synthesized zeolite coating

A zeolite coating was synthesized on a nitrocarburized H13 steel substrate to improve its wear and corrosion resistance using a two-step hydrothermal synthesis approach. The wear test showed that compared with the nitrocarburized H13 substrate, the zeolite-coated sample offered significantly better wear resistance with slightly lower mean coefficient of friction (COF), narrower and shallower wear profiles, and an approximately half wear rate. During the wear process, the protruding corners and edges of the zeolite particles gradually abraded into smooth areas. The wear mechanism of the zeolite-coated H13 sample against the GCr15 grinding ball included the abrasive wear of zeolite particles, formation of a transfer layer, surface oxidation of the wear debris through plastic deformation, and peeling off of the local zeolite particles. Electrochemical and immersion tests showed that the synthesized zeolite coating significantly enhances the corrosion resistance of the steel.

Effects of WC on the Microstructure, Wear and Corrosion Resistance of Laser-Deposited CoCrFeNi High Entropy Alloy Coatings

Wear and corrosion resistant properties of high entropy alloy coatings (HEAC) on H13 steel are of particular interest for industrial applications. The CoCrFeNi HEA/WC composite coatings (HEACC) developed in this study were successfully prepared by incorporating 10–40 wt.% WC into a matrix of CoCrFeNi HEA using laser cladding on an H13 steel substrate. Phase transformation, microstructure evolution, microhardness, wear and corrosion resistance of CoCrFeNi HEACC were investigated. According to the results, all CoCrFeNi HEACC exhibited higher wear and corrosion resistance than the H13 steel substrate. Wear resistance of CoCrFeNi HEACC first increases and then decreases with an increase in the concentration of WC particles, and the lowest coefficient of friction and the shallowest depth of wear groove were observed after adding 30 wt.%. Grain refinement strengthening and second-phase particle strengthening may contribute to enhanced hardness and wear resistance of coatings with WC additions. In addition, all the CoCrFeNi HEACC exhibited improved corrosion resistance. In particular, an addition of 10 wt.% WC helped to significantly improve the corrosion resistance and ease of passivation of CoCrFeNi HEACC.

Microstructural Transformation and High-Temperature Aluminum Corrosion Properties of Co-Based Alloy Coating Prepared by Laser Cladding

A Co-based alloy coating was deposited on H13 steel substrate via pulsed Nd:YAG laser and the corrosion resistance to and mechanism of corrosion in molten aluminum were explored. The results showed that the coating was mainly composed of γ-Co dendrite and M23C6 precipitation. The average hardness in the cladding layer was 732.6 HV0.5, which was 3.55 times greater than that of the H13 substrate. During the molten aluminum corrosion test, the surface of the Co-based alloy coating was immersed for 4, 8, 16 and 24 h at 700 °C. The corrosion rate decreased with increases in aluminum erosion time. It was observed that there were two intermediate layers between the coating and the liquid Al, with (Co, Fe, Cr)2Al9 intermetallic compounds (IMCs) layer near the coating side and the (Fe, Cr)4Al13 and (Co, Fe, Cr)2Al5 intermetallic compounds (IMCs) layer near the Al solidification side. After 24 h of static corrosion, the Co-based alloy coating could still maintain its integrity to protect the substrate.

Single-Track Laser Scanning as a Method for Evaluating Printability: The Effect of Substrate Heat Treatment on Melt Pool Geometry and Cracking in Medium Carbon Tool Steel

Nearly all commercially available alloys have been developed for manufacturing processes other than additive manufacturing. Most of those alloys are not suitable for laser powder bed fusion (L-PBF) processing due to the non-weldable nature of the alloys developed for casting, forging, and machining. Even some weldable alloys can be difficult to produce with L-PBF because the characteristics of L-PBF, such as highly concentrated heat input and the extremely high cooling rate, can lead to very high residual stresses and cracking. In order to speed up the development process of new alloys for additive manufacturing, a powder-free evaluation method was used to evaluate the materials processing window and susceptibility to cracking. Single tracks were scanned with an L-PBF machine onto H13 steel substrates. The substrate condition was varied, and its effect on melt pool geometry and cracking behavior was evaluated. The results clearly show that thermal history of the substrate influences its thermal conductivity, affecting melt pool volume. Melting point of the substrate was not found as significant factor as thermal conductivity on melt pool dimensions. Cracking type was noted to differ between substrates. If printability is assessed without powder, the substrate microstructure should be similar to rapidly solidified material. It is recognized that single-track tests are not adequate in terms of residual stress evaluation, but they can give valuable information about materials’ melting, segregation, and micro-scale cracking behavior.

Enhanced corrosion and wear properties of H13 steel with Co‐based alloy coating prepared by laser cladding

AbstractIn this study, Stellite 21 Co‐based alloy coating was prepared on the surface of the H13 steel substrate by laser cladding. The phase composition, microstructure, chemical constitution, microhardness, and wear property of the coating were studied, respectively. The corrosion resistance of the coating was evaluated by electrochemical test and salt spray test. The results show that the coating is mainly composed of γ‐Co, CoCx, and Cr7C3 phases. γ‐Co solid solution matrix separates within the dendrites, while Mo‐rich intermetallic phases and carbides separate in the interdendritic regions. The average microhardness of the coating is twice that of the H13 substrate. The wear loss of the coating is 74.3% lower than that of the substrate, exhibiting better wear resistance. The main strengthening mechanisms of the coating are solid solution strengthening and second phase strengthening. The self‐corrosion potential of the coating is more positive than that of the H13 steel and the corrosion current density is only 1/160 of the H13 steel. The salt spray test after 168 h reveals that the coating exhibits much better corrosion resistance than that of the substrate.

Investigation on the Corrosion Resistance of Laser Cladding Fe-Based Alloy Coating Against Molten Zinc

In this paper, laser cladding technology was used to prepare an Fe-based coating on H13 steel substrate and its corrosion behavior in molten zinc was studied. The results show that a laser-cladding Fe-based coating can effectively protect the substrate from the corrosion of molten zinc, which is mainly related to its microstructure. The typical microstructure of the coating is composed of α-(Fe, Cr) solid solution matrix and CrFeB eutectic phases continuously distribute around the matrix. When molten zinc is in contact with the surface of the coating, it corrodes the α phase matrix preferentially and CrFeB eutectic phases with better corrosion resistance interweave with each other to form a three-dimensional skeletal structure that can play the role of diffusion barrier and slow down the diffusion rate of liquid zinc. The corrosion by molten zinc leads to the formation of a transition layer and an outer corrosion layer above the coatings. With the prolongation of the corrosion time, a large number of microcracks are generated inside the transition layer and fracture gradually occurs under the action of thermal stress. The partial spalling of the transition layer and the corrosion of α phase matrix occur at the same time, making the corrosion depth of the coating increase continuously. However, the dense corrosion layer above the coating and the dispersed boride fragments can still function as a barrier to the inward diffusion of molten zinc.

Growth and characterization of Rhenium Nitride coatings produced by reactive magnetron sputtering

In this work, thin rhenium nitride (ReNx) films were deposited by reactive radio frequency (R. F.) magnetron sputtering on H13 steel and polished silicon substrates. To improve adhesion to the substrates, a Ti/TiN bilayer was deposited before the ReNx films. Substrate temperature, R.F. power, Ar and N2 gas flow, negative bias voltage, and working pressure were varied in the experiments when synthesizing the ReNx coatings. It was found that lower process pressure and nitrogen flow rate negatively affect the stabilization of coatings and lead to their delamination after they are extracted from the vacuum chamber. Meanwhile, higher nitrogen flow rate and work pressure increase the stability of the coatings by up to several days. Additionally, when the nitrogen flow rate and the negative bias voltage were increased, changes in the crystalline structure of the coatings were observed. However, when the work pressure and N2/Ar ratio were increased and the bias voltage was decreased, the stability of ReNx coatings continued even several weeks after their deposition. X-ray Photoelectron Spectroscopy (XPS) and X-Ray Diffraction (XRD) measurements validated the formation of ReN compound. The more stable deposited rhenium nitride coatings exhibited lower hardness values than the theoretical predictions for this compound, possibly due to the presence of metallic rhenium and thereby rhenium oxides, as seen in the XRD and XPS characterizations.

Microstructure and Tribological Properties of WC-Ni Matrix Cermet Coatings Prepared by Electrospark Deposition on H13 Steel Substrate

Microstructure and Tribological Properties of WC-Ni Matrix Cermet Coatings Prepared by Electrospark Deposition on H13 Steel Substrate

Microstructure and wear resistance of Fe-based, Co-based and Ni-based coating of AISI H13

H13 coating, Stellite156 coating and WC/Ni62 composite coating were prepared on AISI H13 hot working die steel by laser cladding. By means of metallographic microscope, scanning electron microscope, microhardness tester and friction and wear tester, the microstructure, hardness and wear resistance of H13 and three cladding layers were compared and analysed. The results show that H13 alloy coating, Stellite156 alloy coating and WC/Ni62 composite coating all show good metallurgical bonding characteristics with H13 steel substrate. The H13 alloy coating is mainly composed of white reticular dendritic, black intercrystalline carbide, martensite and residual austenite; the Stellite156 alloy coating is mainly composed of primary γ-Co dendrites and eutectic tissues; the WC/Ni62 matrix composite coating is mainly composed of WC particles, dendrites and fine eutectic tissues. The average microhardness of the three cladding layers is obviously higher than that of the substrate. WC/Ni62 composite coating has the best wear resistance under dry wear conditions.

Microstructures and mechanical properties of Ni60 alloy fabricated by laser metal deposition

Due to its low melting point and high hardness, Ni60 (Ni–Cr–B–Si) alloy is widely used as surface cladding material for mould steel. In present study, Ni60 alloy thin-walled samples were fabricated using laser metal deposition (LMD) technology on H13 steel substrate which is usually used as mould material. The microstructure and mechanical properties (microhardness and wear resistance) of LMD Ni60 alloy were investigated. The results show that the LMD Ni60 alloy sample is mainly composed of Ni, Ni3Fe, Ni3B, Ni3Si, CrB, Cr5B3 and Cr7C3. The microstructures of the sample mainly include Ni–B–Si eutectics, Ni columnar dendrites and precipitates (boride and carbide). In the region with faster cooling rate of the sample, eutectics take a larger proportion, meanwhile precipitates are refined and dispersed uniformly. So hardness of the region can reach 950 HV. In the interlayer region, eutectics decrease while Ni dendrites increase because of the influence of remelting. The hardness of this region is about 750 HV. Wear resistance tests indicated that the wear resistance of LMD Ni60 alloy is about 9 times of H13 steel.