High Temperature Wear Resistance Research Articles

The tribological properties of carbon doped Al0.2Co1.5CrFeNi1.5Ti0.5 high entropy alloys

High entropy alloys (HEAs) are expected to be applied at elevated temperatures. However, the tribological properties of the HEAs in a wide temperature range have not been studied systemically, especially at high temperatures. In this paper, the micro-hardness as well as the tribological properties of Al0.2Co1.5CrFeNi1.5Ti0.5+xCx (x = 0, 1.0 and 2.0) HEAs from 25°C to 800°C was investigated and compared with Inconel 718 superalloy. The results showed that the solid solution strengthening effect of the HEAs and the dispersion strengthening effect of in situ generated TiC resulted in a significantly higher high temperature microhardness of the carbon-doped HEAs than that of the Inconel 718. The friction coefficient of the HEAs increased with increasing carbon content at same temperature, but it decreased as the temperature increased. The wear resistance of carbon doped HEAs were superior than that of Inconel 718 and carbon-free HEAs from 25 to 800 °C. Below 600 °C, the wear rate of the HEAs which decreased monotonously with increasing carbon content was in the range of (0.31-12.56) × 10-5 mm3 N-1∙m-1, but above 600 °C, the wear rate of the HEAs was proportion to carbon content within (2.64-23.90) × 10-6 mm3 N-1∙m-1. The excellent high-temperature wear resistance of the HEAs was attributed to the synergistic effect of the good high temperature softening resistance and a nano-oxidized glaze layer with superior mechanical properties on the worn surface.

Processing, microstructure and high temperature dry sliding wear of a Cr-Fe-Hf-Mn-Ti-Ta-V high-entropy alloy based composite

High-entropy materials are promising for high-temperature applications. In order to achieve high-temperature wear resistance, a novel high-entropy alloy based composite, (CrMnFeHf)7.14(TiTaV)23.81, was designed and consolidated by spark plasma sintering at 1320 °C following thermodynamic simulations using the CALPHAD method. The microstructure of the sintered composite revealed a Ti30V36Ta19Cr5Mn5Fe4Hf1 body-centered cubic (bcc) high-entropy alloy matrix with C14 Laves phase and carbide particles. The Laves phase and carbide particles of higher hardness were formed in situ during the sintering in a bcc matrix. The dry sliding wear behavior of the composite against Si3N4 ceramic counter ball (10 N, 30 min) from room temperature to 600 °C was investigated. The high-entropy alloy composite showed a superior resistance to wear against Si3N4 ceramic due to the presence of reinforcing C14 laves phase and carbide particles in the high-entropy alloy matrix. Furthermore, the wear rate reduced with increasing temperature. The dominating wear mechanisms of the high-entropy alloy composite were adhesive wear and abrasive wear at room temperature and 200 °C, oxidation wear and abrasive wear at 400 °C and oxidation wear and delamination wear at 600 °C. The formation of multiple oxides, presence of Laves and carbide phase contributed to the low volume loss of high-entropy alloy composite during wear tests at high temperatures.

Research on gradient additive remanufacturing of ultra-large hot forging die based on automatic wire arc additive manufacturing technology

In this paper, an automatic WAAM technology is proposed to realize the gradient additive remanufacturing of ultra-large hot forging dies. Firstly, a vertical additive manufacturing strategy and a normal additive manufacturing strategy are proposed to meet different additive manufacturing demands. Secondly, the basic principle of layering design of ultra-large hot forging dies is developed, and the wear resistance of Ni-based, Co-based, and Fe-based alloys at room temperature and high temperature is analyzed. The Co-based alloy has the best high-temperature wear resistance, which can be used on the surface of the hot forging die to strengthen the die. In order to control the forming quality of additive manufacturing, the relationship between welding parameters and weld shape was discussed, and the reverse system of welding process parameters was built. Finally, a typical aviation ultra-large hot forging die is selected as the research object. According to different stress and temperature distribution in different regions of the ultra-large hot forging die in service, materials with different properties are used in corresponding regions to improve the service life of the die, reduce the remanufacturing costs, and improve the remanufacturing efficiency. The experimental results show that the service life of the hot forging dies repaired by the automatic gradient function WAAM technology is significantly increased, the material is reduced by more than 50%, and the production efficiency is increased by more than 50%.

Effect of c-BN on the microstructure and high temperature wear resistance of laser cladded Ni-based composite coating

In this study, Ni-based Ni60 + Cu/h-BN + MoO3 and Ni60 + Cu/c-BN + MoO3 composite coatings were fabricated by laser cladding on a Q235 substrate. Compare with the addition of h-BN, the effect of c-BN on the microstructure, high temperature hardness and wear resistance properties of the coating from 25 °C to 800 °C were analyzed. The results show that part of c-BN is decomposed during laser cladding process, resulting in the formation of Cr(Mo)B, Cr5B3, CrN and MoN reinforcements. The periphery of the remaining c-BN particle is allotropic transformed to h-BN under laser irradiation. The content of the reinforcement in the coating is increased and the distribution is more uniform, therefore, the hardness of the coating is increased. This resulted in a reduction of the wear rate from 25 °C, 200 °C, 400 °C, 600 °C to 800 °C by 77%, 61%, 29%, 46% and 39%, respectively. The abrasive and adhesive wear are released because of the increasing of deformation resistance and interface strength of γ-(Ni, M) matrix and Cr(Mo)B. In the meantime, the formation of h-BN provides lubricating property over the wide temperature range.

High temperature wear performance of laser cladding maraging steel with low nickel on AISI H13 steel

H13 steel is prone to insufficient high temperature wear resistance due to thermal wear under high temperature conditions. To improve high temperature wear resistance of H13 steel, the maraging steel coating with low-nickel was successfully prepared owing to excellent thermal stability. Sliding wear tests at 400, 500 and 600 °C were carried out for the laser cladding coating and H13 steel to comparatively investigate their high temperature wear performance and mechanism. The microstructure, phases, hardness and thermal stability of the maraging steel coating were also studied. The results showed that the maraging steel coating possessed excellent high temperature wear resistance and effectively improved the high temperature wear resistance of H13 steel by laser cladding. The superior thermal stability of maraging steel played an important role in improving its high temperature wear resistance.

Microstructure and high-temperature properties of laser cladded AlCoCrFeNiTi0.5 high-entropy coating on Ti 6Al-4V alloy

In this study, AlCoCrFeNiTi 0.5 high-entropy alloy (HEA) coating was deposited on Ti-6Al-4V alloy by laser cladding, aiming at enhancing the high-temperature wear and oxidation resistance . The microstructure, hardness, oxidation performance as well as high-temperature wear of the coating were characterized respectively. The results indicated that the coating was composed of dendrite (DR) and interdendrite (IR) phases. The DR phase had FCC structure being rich in Al, Co, Ni and Ti. The IR phases had BCC structure, for which, the IR1 was rich in Fe and Cr, and the IR2 was rich in Fe, Cr, Ti, Co and Ni. The coating possessed much better oxidation resistance than Ti-6Al-4V alloy at 600 °C due to a more compact oxide surface and the sluggish diffusion effect, which impeded the subsequent oxidation effectively. The average oxidation rate of the coating was about one tenth that of Ti-6Al-4V alloy. Moreover, the oxide scale was about one fifth that of Ti-6Al-4V alloy. The average micro-hardness of the coating was 706.3 HV about 2.32 times that of Ti-6Al-4V alloy. The HEA coating exhibited a mixture wear mechanism of adhesive and oxidative wear at 600 °C, having a wear volume loss about one thirteenth that of Ti-6Al-4V alloy. • AlCoCrFeNiTi 0.5 coating was fabricated on Titanium alloy by laser cladding. • Microstructure, behaviors of wear and oxidation at 600 °C were investigated. • The wear and oxidation resistance was improved by 12 and 9 times respectively. • The oxides of the coating was mainly Al 2 O 3 and Cr 2 O 3 at 600 °C. • The coating endured both adhesive and oxidative wear at 600 °C.

Microstructure, High-Temperature Wear Resistance, and Corrosion Resistance of Laser Cladded Co-Based Coating

Co-based coating has been fabricated on Ti-6Al-4V (TC4) titanium alloy by laser cladding. The phase composition and microstructure of the coating were analyzed using metallurgical microscope (MM), scanning electron microscope (SEM), x-ray diffraction (XRD), energy-dispersive spectroscopy (EDS) and transmission electron microscopy (TEM), respectively. The microhardness, high temperature wear resistance and corrosion resistance of the coating were investigated by performance tests. The results show that the coating was mainly composed of CoTi, CoTi2 and Co0.5Cr1.5Ti crystalline phases and an amorphous phase. The microhardness of the coating was twice that of the titanium alloy substrate. The value of friction and wear coefficient of the coating was lower and more stable, and the wear mass loss decreased by 52% as compared with the substrate in the high-temperature friction and wear test. The oxidative wear mechanism in the condition of high temperature friction and wear was studied. Moreover, the coating exhibited better corrosion resistance than the substrate in both NaCl and H2SO4 electrolyte solutions.

Filling Path Planning and Polygon Operations for Wire Arc Additive Manufacturing Process

To improve the service life of hot forging die, the additive manufacturing algorithm and additive manufacturing device for die remanufacturing are developed. Firstly, a compound filling algorithm in which the inner zone is filled by linear scanning and the outer contour is filled by offsetting is developed in order to solve the problems encountered in filling path planning for wire arc additive manufacturing (WAAM) like staircase effect at marginal division, degenerated edge at outer contour, programming difficulty, and so forth. Meanwhile, the attitude control algorithm of welding gun is proposed to control the angle between welding gun and welding path so as to improve the welding forming quality. Secondly, the high-temperature and low-temperature wear resistances of Fe-based and Ni-based alloy are tested. The results show that Ni-based alloy has higher high-temperature wear resistance. Finally, a disabled crankshaft hot forging die is selected for application test and the results show that, using the techniques discussed in this paper, welding materials can be saved by more than 50% and machining cost can be saved by more than 60%. In addition, the surface of automatic-repaired die is smooth without oxidation, collapse, and other defects after forging 3000 times, which is much better than that of manual-repaired die.

Double Glow Plasma Nitriding Pretreatment of TiAlN-Coated TA15 Alloy for Enhancement of Bonding Strength and Mechanical Properties

As a classic hard coating, titanium aluminum nitride (TiAlN) coating is widely applied in the aviation field due to its extremely high hardness and strength. Unfortunately, the large difference in hardness and thermal expansion coefficient between the coating and the substrate could also lead to the reduction of bonding force. In this paper, Double-glow plasma nitriding (DGPN) pretreatment followed by RF magnetron sputtering was used to prepare DGPN-TiAlN coating on the surface of TA15 alloy. The adhesion and the bearing capacity of DGPN-TiAlN coating is characterized by scratch and indentation tests. The gradient hardness support and stress transition effect of the nitriding layer are significant, and the bonding strength of TiAlN coating and the substrate are significantly improved. In addition, the high temperature wear resistance and erosion resistance of DGPN-TiAlN coating were detected through high-temperature wear tests and sand erosion tests. At 500 °C, the surface of DGPN-TiAlN coating formes a dense Al2O3 lubricating film with good adhesion, and the friction coefficient is lower than that of TiAlN coating. Under different erosion speeds and erosion angles, the erosion rate of DGPN-TiAlN coating is lower than that of TiAlN coating, and the coating surface defects are less.

Cobalt-based alloy surfacing process optimization and surfacing material performance analysis

In order to solve the problem of the failure of the UMCo50 process burner, the orthogonal test was used to optimize the UMCo50 cobalt-based alloy TIG surfacing process, better joint performance was obtained for welding current of 120 A, surfacing speed of 12 cm min−1, interpass temperature of 50 °C and surfacing layer of 2 ∼ 3 layers; Tungsten inert gas(TIG) welding and plasma transferred arc weld(PTAW) surfacing were used to surfacing UMCo50 welding wire and T800 cobalt-based alloy powder on UMCo50 base metal. The structure, hardness, high temperature wear resistance and heat corrosion resistance of the surfacing layer were compared. The results show that UMCo50 surfacing layers are α-Co (fcc) and ε-Co (hcp); T800 alloy surfacing layers are mainly Co3Mo2Si, CoMoSi, α-Co and ε-Co. The Laves phase in the T800 alloy surfacing layer significantly improves its hardness and high temperature wear resistance; Under the same test conditions, the heat and corrosion resistance of the UMCo50 surfacing layer is significantly better than that of the T800 surfacing layer.

High temperature phase stability and wear behavior of laser clad Ta reinforced NiCrBSi coating

Ta is added to laser clad NiCrBSi coating to improve high-temperature wear resistance. The influence of heat treatment of 700 °C on Ta reinforced coating is studied. The microstructure is analyzed by XRD, SEM, EDS, TEM and XPS. The tribological performances were investigated on high temperature pin-on-disk tribometer at temperatures up to 700 °C. Ta reinforced coating mainly includes γ-Ni, TaC, Ni3Fe, CrB, M23C6 and Cr2.8Fe1.2B4. Under heat treatment, most of the phases remain stable except that M23C6 is dissolved and coarsened. CrB formed on TaC particle is evolved into Cr2.8Fe1.2B4. The heat treatment has little influence on the hardness of Ta reinforced coating. It is difficult to form an oxide layer on worn surface of NiCrBSi coating at any temperature. On the contrary, an oxide layer form on worn surface of Ta reinforced coating at 700 °C. Ta significantly improves the wear resistance of NiCrBSi coating at high temperatures, which is attributed to Ni matrix strengthened by Ta, TaC with high thermal stability, clean TaC/matrix interface, and compact oxide layer. The main wear mechanism below 600 °C is abrasion and adhesion, and oxidization, which transitions to delamination, abrasion, ploughing and oxidization at 700 °C.

Effect of surface modification through GTAW on high-temperature performance of 4Cr5MoSiV steel

In the study, the surface modification of 4Cr5MoSiV steel through gas tungsten arc welding (GTAW) was carried out. X-ray diffraction (XRD) and scanning electron microscopy (SEM) were used to investigate the evolution of phases and microstructures before and after the GTAW surface modification treatment. The microhardness, tribological behavior, and high-temperature oxidation property were systematically investigated using the tests regarding microhardness, high-temperature wear, and high-temperature oxidation. GTAW remelting process generated (FCC + BCC) dual phase, which created mutual restriction between the two phases in plastic deformation. Continuous distribution of hard Cr3C2 carbides at grain boundaries could disperse local stresses. The microhardness of the GTAW remelting layer was significantly improved, and the GTAW remelting increased the V element of the free state and formed V2O5 oxide with unique lattice structure in the oxide layer. The high-temperature oxidation performance of the GTAW remelting layer was slightly deteriorated. The high-temperature oxidation duration for the high-temperature wear test was short, and the high hardness of remelting layer and the connective carbides together played the major roles, so GTAW remelting layer had excellent resistance to high-temperature wear resistance.

Study on Wear Resistance of Ti-6Al-4V Alloy Composite Coating Prepared by Laser Alloying

Titanium alloy has extensive applications in numerous fields, such as in aerospace, shipbuilding, petrochemical, and bio-medical. However, under the condition of high temperature (above 700 °C), it is difficult to meet the requirements of the performance of the turbine blades, piston rings, valves, etc. In this paper, the alloy powder is composed of Ni60A, TiN, Al, and Si in accordance with the proportion of 1:3:4:2 (mass ratio), and the composite coating, such as TiN, TiB, Ti5Si3, and Al3Ti were synthesized on Ti-6Al-4V alloy by Yttrium Aluminium Garnet(YAG) laser. The friction and wear experiments were carried out on Ti-6Al-4V alloy and alloyed coatings at different loads (3N, 6N, 9N), and different temperatures (25 °C, 350 °C, 700 °C). The impact of load and temperature on wear performance were analyzed by analyzing the friction traces. The results showed that the abrasion loss, wear width, and depth, wear volume, and wear ratio of the alloyed coatings were less than Ti-6Al-4V alloy, and the surface of furrow was shallow and the wear was less. However, under high temperature conditions, the alloy coating wears worse than Ti-6Al-4V alloy, and the high temperature wear resistance is not ideal.

Corrosion resistance and high temperature wear behavior of carbide-enhanced austenite-based surfacing layer prepared by twin-wire indirect arc welding

Twin-wire indirect arc welding is a novel welding process. In this article, the anode wire was an austenite-based welding wire, and the cathode wire was an iron-based wear-resistant welding wire. Given that the two wires burn simultaneously in twin-wire indirect arc welding, a carbide-enhanced austenite-based surface layer was produced. The high-temperature wear resistance of the austenitic stainless steel was enhanced by the carbides. Results indicated enhancements in amount of reinforcing phase in the austenite-based surface layer with increasing of cathode wire feeding speed and the high-temperature friction coefficient decreased first and then increased. However, the corrosion resistance of austenite-based surfacing layer decreased slightly with increasing of amount of reinforcing phase. At low content of the reinforcing phase in the surface layer, the high-temperature wear behavior was dominated by oxidative adhesive wear, which changed to abrasive wear with the increase in the reinforcing phase.

Microstructure and high-temperature wear behaviour of Inconel 625 multi-layer cladding prepared on H13 mould steel by a hybrid additive manufacturing method

To improve the high-temperature performance of a hot-working mould, high-temperature wear-resistant multi-layer laser cladding was prepared on the forming surface of the mould by a hybrid additive manufacturing (HAM) method. First, an Inconel 625 multi-layer cladding was fabricated on the H13 mould steel by laser cladding. Then, the multi-layer laser cladding was milled by CNC. Finally, the milled multi-layer cladding was subjected to ultrasonic surface rolling (USR) treatment. The microstructure and high-temperature wear behaviour of the multi-layer cladding prepared by HAM were studied using SEM, EDS, and a high-temperature tribometer. The results show that the multi-layer laser cladding after USR has a smooth nanolayer. The surface roughness is below 0.15 μm. The multi-layer cladding has better high temperature wear resistance than the substrate. The microstructure of the multi-layer cladding from the surface to the substrate is composed of coaxial, columnar, and dendritic grains. After USR treatment, the dendritic grains are grown in the processing direction and significantly refined.

Phase Transformation-Induced Improvement in Hardness and High-Temperature Wear Resistance of Plasma-Sprayed and Remelted NiCrBSi/WC Coatings

The remelting method is introduced to improve the properties of the as-sprayed NiCrBSi coatings. In this work, tungsten carbide (WC) was selected as reinforcement and the as-sprayed and remelted NiCrBSi/WC composite coatings were investigated by X-ray diffraction, scanning electron microscopy, hardness test and tribology test. After spraying, WC particles are evenly distributed in the coating. The remelting process induced the decarburizing reaction of WC, resulting in the formation of dispersed W2C. The dispersed W2C particles play an important role in the dispersion strengthening. Meanwhile, the pores and lamellar structures are eliminated in the remelted NiCrBSi/WC composite coating. Due to these two advantages, the hardness and the high-temperature wear resistance of the remelted NiCrBSi/WC composite coating are significantly improved compared with those with an as-sprayed NiCrBSi coating; the as-sprayed NiCrBSi coating, as-sprayed NiCrBSi/WC composite coating and remelted NiCrBSi/WC composite coating have average hardness of 673.82, 785.14, 1061.23 HV, and their friction coefficients are 0.3418, 0.3261, 0.2431, respectively. The wear volume of the remelted NiCrBSi/WC composite coating is only one-third of that of the as-sprayed NiCrBSi coating.

Effect of CeO2 on high-temperature wear resistance of WC/Fe-based coatings

ABSTRACT In this study, the WC reinforced Fe-based composite coatings with various CeO2 contents were fabricated on the H13 hot-working die steel by laser cladding. The high-temperature wear resistance of composite coatings was analysed by friction-abrasion testing machine, white light interferometer, and scanning electron microscope (SEM). The microstructure and microhardness were investigated by SEM and Vickers hardness tester. The influence mechanism of CeO2 on microstructure and wear resistance was explained. The results showed that appropriate CeO2 could effectively refine the microstructure of coatings, and affect the crystal morphology. The microhardness of composite coatings was about 4–5 times that of the die steel substrate. Affected by microstructure and microhardness, the Fe-based composite coatings with CeO2 exhibited a higher high-temperature wear resistance than the substrate.

Oxidation and Wear Mechanisms of FeCoCrNiMnAlx Cladding Layers at High-Temperature Condition

FeCoCrNiMnAlx high-entropy alloy (HEA) cladding layers were successfully fabricated on H13 steel by laser cladding. The microstructure and properties of the FeCoCrNiMnAlx HEA cladding layers were systematically studied. The influence of Al content on high-temperature wear resistance of HEAs was investigated by depth-of-field microscopy, XRD, SEM and EDS. Addition of Al element affected the mechanism of oxidation and strengthening of the cladding layers, and effectively promoted its anti-oxidant and abrasion resistance. Compared with the FeCoCrNiMn cladding layer, the FeCoCrNiMnAl0.75 cladding layer enhanced the anti-plastic deformation capacity by 7.1% and reduced oxidation weight gain and total wear weight loss at high temperature by 36.79% and 79.0%, respectively. The wear mechanisms of the cladding layer at high temperature were mainly oxidation wear and abrasive wear, while adhesive wear took a backseat.

Room- and high temperature Wear Resistance of MCrAlY Coatings Deposited by Detonation Gun (D-gun) and Supersonic Plasma Spraying (SSPS) Techniques

In this study, CoNiCrAlY metallic coatings were deposited on an Inconel 718 nickel-based superalloy substrate material using the detonation gun (D-gun) and supersonic plasma spraying (SSPS) techniques. The microstructural and mechanical properties in addition to their room and high temperature wear behavior of the produced coatings were evaluated. The wear tests were performed at room temperature (rt), 250 and 500 °C using 2N and X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS) analyses of the worn coatings were performed to assess their wear performance. The coatings produced with D-gun process exhibited higher hardness and lower porosity (550 ± 50 HV0.25 hardness and 1.2 ± 1.0% porosity) than SSPS coatings (with 380 ± 30 HV0.25 hardness and 1.5 ± 1.0% porosity) which resulted in better room- and high temperature wear performance for D-gun coatings. The worn surfaces of both coatings exhibited formation of tribological layers and superficial microstructural changes by varying temperature and load conditions. Increasing load and temperature resulted in increased wear loss whereas increasing temperature resulted in reduced COF values for both coatings.

Microstructure and dry sliding wear behavior of as-cast TiCp/Ti-1100-0.5Nb titanium matrix composite at elevated temperatures

The microstructure and dry sliding wear performance of as-cast TiCp/Ti-1100-0.5Nb composite at 25 °C, 500 °C and 600 °C were systematically investigated. Results show that the solidification matrix microstructure is the typical Widmanstatten structure. The eutectic TiC particles are uniformly distributed in the matrix in the form of feathery, long rod and strip-like shapes. Meanwhile, the interface between TiC and titanium matrix is clear and without any reaction. The wear rate of TiCp/Ti-1100-0.5Nb at 600 °C and 500 °C is reduced by 95.8% and 79.9%, respectively, compared with that of the value of 51.8×10−6 mm3·mm−1 at 25 °C. The friction coefficient of the steady-state period at 25 °C, 500 °C, 600 °C is 0.48, 0.8, 1.2, respectively, and the variation extent of the friction coefficient at elevated temperatures is greater than at 25 °C. The wear mechanism is changed from the mixture of adhesive wear and abrasive wear to mild oxidation wear with rising temperature. It can also be concluded that the composite possesses excellent high temperature wear resistance. The high-wear resistance of the composite is attributed to the Fe2O3 and TiO2. The presence of Fe2O3 and TiO2 reduces the wear rate, increases the friction coefficient, and also improves the range-ability of the friction coefficient.