Wear Resistance Of Coatings Research Articles

Comparison of High-Temperature Wear Resistance of Gas-Flame and Ion-Plasma Sealing Coatings with 0.1% Yttrium

Wear-resistant sealing coatings of KNA-82 system with 0.1% yttrium addition for hot parts of gas-turbine engines, applied by gas-flame and ion-plasma methods, are considered. The introduction of yttrium increases the operating temperature from 900°C to 1100°C. The methodology of modeling of processes of contact interaction of engine parts under operating conditions has been developed. Tribotechnical tests modeling the contact of the coating surface with the rotor ridge tops and blade feathers have been carried out, after which linear wear has been measured and the results have been statistically processed. The gas-flame coatings show slower wear reduction at temperatures up to 800°C, while both coatings show similar properties at 1100°C. The improved properties are attributed to the formation of phase-like Ni3Y compound in the grain boundaries.

Effect of Electromagnetic Field Assistance on the Wear and Corrosion Resistance of Nickel-Based Coating by Laser Cladding

Offshore wind turbine generators usually demand higher requirements for key component materials because of the adverse working environment. Therefore, in this study, electromagnetic-assisted laser cladding technology was introduced to prepare the nickel-based composite coating on the Q345R matrix of wind turbine generator key component material. By means of Scanning Electron Microscope (SEM), X-ray diffraction (XRD), Energy Dispersive Spectrometer (EDS), the Vickers hardness tester, friction and wear tester, and electrochemical workstation, the effects of different magnetic field intensities on the macroscopic morphology, microstructure, phase composition, microhardness, wear resistance, and corrosion resistance of the coating were analyzed. The experimental results show that the addition of a magnetic field can effectively reduce the surface defects, improve the surface morphology, and not change the phase composition of the coating. With the increase in magnetic field intensity, the microstructure is gradually refined, and the average microhardness increases gradually, reaching a maximum of 944HV0.5 at 8 T. The wear resistance gradually increases with the increase in magnetic field intensity, especially when the magnetic field intensity reaches 12 T, the wear rate of the coating is reduced by 81.13%, and the corrosion current density is reduced by 43.7% compared with the coating without a magnetic field. The addition of an electromagnetic field can enhance the wear resistance and corrosion resistance of the nickel-based laser cladding layer.

Electrospark Deposition of Hard, Wear-Resistant and Anti-Friction Tribological Coatings on γ-TiAl Substrates in a Controlled Gas Environment

Electrospark Deposition of Hard, Wear-Resistant and Anti-Friction Tribological Coatings on γ-TiAl Substrates in a Controlled Gas Environment

Microstructure, hardness, and tribological properties of Ni-Co/ SiO2 nanocomposite coating produced through pulsed current electrodeposition

This study investigates the development of Ni-Co/SiO2 nanocomposite coatings on mild steel surface using pulsed-current electrodeposition method. The effects of incorporating SiO2 nanoparticle and varying its concentration on the coatings' microstructure, microhardness, wear resistance, and frictional properties were assessed using field-emission electron microscopy, X-ray diffraction, Vickers microhardness testing, and dry sliding wear tests. The results indicated that the coatings exhibited two-phases of Ni-Co solid solution (α) with a face-centered cubic (FCC) crystal structure and hexagonal Co, a refined crystallite size of approximately 31 nm for Ni-Co and about 25 nm for Ni-Co/SiO2, along with a colony-like morphology that did not show any preferred growth direction. The amount of Ni-Co solid solution increased with the addition of SiO2 nanoparticles. The composite coatings demonstrated enhanced microhardness of 581 HV, which is 52 % greater than that of the Ni-Co coating, as well as improved wear resistance and a reduced friction coefficient compared to the unreinforced alloy coating. However, higher SiO2 content adversely impacted the tribological properties due to nanoparticle agglomeration. Analysis of the worn surfaces revealed a transition from abrasive wear to oxidative wear with increasing applied force for the coatings.

Effect of chemical inhomogeneity on the structure and properties of the two-layer TiAl-based coating obtained by non-vacuum electron beam cladding: Experimental investigations and density functional theory simulations

Non-vacuum electron beam cladding is a highly effective technology for producing protective coatings on metal workpieces. In this study, the 3.8 mm thick TiAl-based coating with Cr and Nb additions was obtained on the Ti alloy substrate in two passes of the electron beam. To evaluate inhomogeneity of the two-layer coating, energy-dispersive synchrotron X-ray diffraction (EDSXRD) in combination with energy-dispersive X-ray spectroscopy (EDX) was applied. It was found that in the direction from the top of the coating to the substrate, the dilution of the cladding layers with Ti increased. It influenced the phase constitution of the coating and led to a variation in the chemical composition of different phases (α2-Ti3Al, β-phase, and TiN). The properties of the first (lower) and the second (upper) cladding layers were evaluated separately. The upper layer exhibited greater oxidation resistance than the lower one due to the presence of the γ-phase, which has superior high-temperature stability compared to the α2-Ti3Al phase, predominant in the coating. The influence of varying chemical composition on the oxidation resistance was also estimated using density functional theory (DFT) simulations. It was found that decrease in Al content in the α2 phase leads to an increase in oxygen absorption energy. This could potentially result in a decrease in oxidation resistance. Wear resistance of the first and the second cladding layers was at the same level mainly due to the low contribution of minor phases. Additionally, DFT simulations show that the variations in chemical composition of the major phase (Ti3Al) are not likely to impact the coating wear resistance.

DEPOSITION BEHAVIOR OF WC-17Co COLD-SPRAYED COMPOSITE COATING ON HYDRO TURBINE STEELS

Cold spraying is a promising technique for depositing wear-resistant coatings on components like hydroturbine steels. This paper highlights the feasibility of hard WC-17Co coating on 13Cr4Ni hydroturbine steel. The coating was deposited at 25, 30, and 40 bar at 800∘C and 50 bar at 900∘C. Further, different characterization techniques (SEM, XRD) were used to analyze the developed coatings. The Vicker hardness testing was employed to determine the hardness of the coated sample. It was observed that WC-17Co coatings deposited at 40 bar and 800∘C offered a maximum hardness of up to 275 Hv, which is an excellent quality for anti-wear applications in hydro turbine blades.

Dual-Function Double-Walled Microcapsules Effectively Improve the Wear Resistance and Anticorrosion of Epoxy Composite Coatings

Dual-Function Double-Walled Microcapsules Effectively Improve the Wear Resistance and Anticorrosion of Epoxy Composite Coatings

Wear performance of CoCrFeMnNi and CoCrFeMnNi-SiC coatings on 0Cr18Ni9Ti stainless steel fabricated by plasma transfer arc cladding

To enhance the wear resistance of stainless steel, CoCrFeMnNi and CoCrFeMnNi-SiC coatings were deposited on 0Cr18Ni9Ti via plasma transfer arc cladding. Effects of SiC particles on microstructure, microhardness and tribological properties of the CoCrFeMnNi coating were investigated. Results demonstrate that, in addition to the FCC solid solution and a small amount of oxide, the CoCrFeMnNi-SiC coating contains M23C6 and M7C3 phases, which exhibit an average hardness approximately 2.3 times that of the CoCrFeMnNi coating. Meanwhile, the wear resistance of the composite coating under different loads was improved, which was attributed to the fact that the high hardness SiC reduced the shear and adhesion between the coating and the mill ball, and the composite coating received abrasive and oxidative wear.

The Microstructure and Properties of Ni60/60% WC Wear-Resistant Coatings Prepared by Laser-Directed Energy Deposition.

Ni60/60% WC composite coatings with a good surface roughness and high mechanical properties were successfully prepared on 316L stainless steel substrate by laser-directed energy deposition (LDED) technology. The effects of laser power on the microstructural evolution and mechanical properties of the Ni60/60% WC composite coating were investigated. The relationships between the chemical composition, the microstructure, the hardness, and the friction wear resistance of the composite coatings were characterized and investigated. The results show that the laser power had a significant effect on the energy input, which determined the melting extent of the Ni60 phases around the WC particles and the bonding strength between the reinforcements and the matrix, as well as the bonding strength between the substrate and the coatings. With an increase in the laser power from 800 W to 1400 W, the average hardness of the coating surface increased due to the increased densification of the deposited coatings and then decreased due to grain coarsening under a high energy input. The average coefficient of friction of the coatings decreased gradually to 0.383 at 1000 W, showing a minimum wear of 0.00013 mm2 at 1200 W. The main wear mechanisms on the coated surfaces were adhesive wear and abrasive wear. Moreover, the coatings deposited at 1200 W exhibited better forming quality and wear resistance. This work suggests that the processing parameters during LDED can be optimized to prepare Ni60/60% WC wear-resistant coatings with excellent mechanical properties.

Corrosion and wear resistant advanced coatings for typical engineering applications

This special issue highlights the original research on the advanced coatings used in the various industrial applications.

Boosted Gasoline Transport Performance of Poly(vinyl alcohol) Tubes by Constructing Wear-Resistant and Hydrophobic Coatings on the Surface

Boosted Gasoline Transport Performance of Poly(vinyl alcohol) Tubes by Constructing Wear-Resistant and Hydrophobic Coatings on the Surface

Construction of hard BCC phases FeCrVMnTix wear-resistant high-entropy alloy coatings enhanced by solid solution of Ti elements

To address the complex working conditions encountered by 1Cr13 ferritic/martensitic steel during operation, it is imperative to develop high-entropy alloys (HEAs) protective coatings with enhanced friction resistance. In this work, guided by the valence electron concentration criterion, we constructed a single-phase body-centered cubic (BCC) structure with high hardness. This was achieved through the introduction of titanium (Ti), which has a significantly different atomic radius compared to other elements. FeCrVMnTix (x = 0, 0.5, 1.0, 1.5, and 2.0) coatings were fabricated on 1Cr13 steel surfaces using laser cladding techniques, and the microstructure, mechanical properties, and wear-resistance properties of Ti-doped HEA coatings were investigated. The results reveal that the FeCrVMnTix coatings are comprised of a BCC solid solution. Increasing Ti content refined the dendritic structure of the coatings, enhancing the Vickers hardness from 4.35 GPa to 8.27 GPa and the Young's modulus from 232.6 GPa to 273.2 GPa. Additionally, the wear rate decreased from 3.07 × 10−5 mm3·N−1·m−1 to 4.94 × 10−6 mm3·N−1·m−1. Notably, the FeCrVMnTi2.0 coating demonstrated excellent wear resistance that can be attributed to the solid solution strengthening effect of Ti. These findings underscore the pivotal role of Ti in enhancing the wear resistance of the coatings.

Wear and Corrosion Resistances of Arc-Sprayed FeCr Alloy and Fe-Based Coatings for Boiler Heat Exchanger Pipelines

Wear and Corrosion Resistances of Arc-Sprayed FeCr Alloy and Fe-Based Coatings for Boiler Heat Exchanger Pipelines

Exploring the dual effect of sodium lignosulfonate-modified LDH treatment and heat processing on elevating corrosion and wear resistance of Ni-W composite coatings

The exploration of Ni-W composite coatings with high corrosion and wear resistance is highly important for engineering applications. In this study, LDH-SLS composite nanomaterials were synthesized via hydrothermal synthesis, and Ni-W/SLS composite coatings with excellent wear and corrosion resistance were prepared via pulsed electrodeposition combined with heat treatment. The successful synthesis of LDH-SLS was confirmed by TEM, EDS, FTIR, XPS and XRD analyses. Furthermore, multipoint BET specific surface area analyses demonstrated that pore size and the specific surface area of the LDH materials were enhanced by SLS. Corrosion studies showed that the Ni-W/SLS coatings with the addition of the LDH-SLS nanomaterial had higher impedance compared to the Ni-W coatings. And the Ni-W/SLS coating can show better corrosion resistance after heat treatment at 400°C with an impedance of 2.98 ×104 Ω·cm2, which is 502.2 % higher than that of the Ni-W coating, and a corrosion current of 7.2399 ×10−7 A/cm2, which is two orders of magnitude lower than that of the Ni-W coating. Comparative analyses of coating microhardness, friction curves and average friction coefficients show that heat treatment at appropriate temperatures can significantly improve the wear resistance of Ni-W coatings. The Ni-W/SLS coatings heat treated at 400°C showed the most desirable wear resistance. This study presents a new method for producing Ni-W coatings with high corrosion and wear resistance.

Molecular Dynamics Study on Wear Resistance of High Entropy Alloy Coatings Considering the Effect of Temperature.

High entropy alloys have excellent wear resistance, so they have great application prospects in the fields of wear resistance and surface protection. In this study, the wear resistance of the FeNiCrCoCu high entropy alloy coating was systematically analyzed by the molecular dynamics method. FeNiCrCoCu high entropy alloy was used as a coating material to adhere to the surface of a Cu matrix. The friction and nanoindentation simulation of this coating material were carried out by controlling the ambient temperature. The influence of temperature on its friction properties was analyzed on five aspects: lattice structure, dislocation evolution, friction coefficient, hardness, and elastic modulus. The results show that with the increase of temperature, the disorder of the lattice structure increases, which leads to an increase of the tangential force and friction coefficient in the friction process. At 300 K and 600 K, the ordered lattice structure of the high entropy alloy coating material is basically the same, and thus its hardness is basically the same. However, the dislocation density at 600 K is significantly reduced compared with that at 300 K, resulting in an increase of the elastic modulus of the material from 173 GPa to 219 GPa. At temperatures of 900 K and 1200 K, lattice disorder takes place rapidly, and dislocation density also decreases significantly, resulting in a significant decrease in the hardness and elastic modulus of the material. When the temperature reaches 900 K, the wear resistance of the FeNiCrCoCu high entropy alloy coating decreases sharply. This work is of great value in the analysis of wear resistance of high entropy alloys at high temperature.

The Influence of Adding B4C and CeO2 on the Mechanical Properties of Laser Cladding Nickel-Based Coatings on the Surface of TC4 Titanium Alloy.

The development of titanium alloys is limited by issues such as low hardness, poor wear resistance, and sensitivity to adhesive wear. Using laser cladding technology to create high-hardness wear-resistant coatings on the surface of titanium alloys is an economical and efficient method that can enhance their surface hardness and wear resistance. This paper presents the preparation of two types of nickel-based composite coatings, Ni60-Ti-Cu-xB4C and Ni60-Ti-Cu-B4C-xCeO2, on the surface of TC4 titanium alloy using laser cladding. When the B4C addition was 8 wt.%, the hardness of the cladding layer was the highest, with an average microhardness of 1078 HV, which was 3.37 times that of the TC4 substrate. The friction coefficient was reduced by 24.7% compared to the TC4 substrate, and the wear volume was only 2.7% of that of the substrate material. When the CeO2 content was 3 wt.%, the hardness of the cladding layer was the highest, with an average microhardness of 1105 HV, which was 3.45 times that of the TC4 substrate. The friction coefficient was reduced by 33.7% compared to the substrate material, and the wear volume was only 1.8% of that of the substrate material.

Electrophoretic deposition of MXene coating on Mg alloy 2,5 PDCA-LDH film for enhanced anticorrosion/wear

Two-dimensional (2D) MXene, employed as protective coatings for anticorrosion and wear resistance, outperforms most state-of-the-art 2D nanomaterials. In this work, MgAl-LDH film modified with the 2,5 PDCA inhibitor was synthesized on Mg alloy AZ31 via in-situ hydrothermal methods. Subsequently, MXene Ti3C2 at various concentrations was electrophoretically deposited onto the as-prepared 2,5 PDCA-LDH film. The successful incorporation of the 2,5 PDCA inhibitor resulted in MgAl-LDH nanosheets with a low growth angle, facilitating the electrophoretic deposition of MXene Ti3C2. After deposition, Ti3C2 nanomaterials uniformly coated the 2,5 PDCA-LDH film, forming a protective barrier against corrosive species while simultaneously establishing a lubricating layer. Notably, Ti3C2 nanosheets exhibit a tendency to self-agglomerate at higher concentrations, resulting in the 1.0 wt% Ti3C2 coating displaying the highest anticorrosion and lubrication capacities.

Study on microstructure and wear resistance of laser cladding TiAlZrVNiX high entropy alloy coating based on Laves phase modulation

The incorporation of Laves phase into HEAs coating represents a novel approach to enhance wear resistance, building upon the innovative background of titanium alloy surface protection. The TiAlZrVNiX (X = 1, 1.5, 2) HEAs coatings were prepared in this study using laser cladding advantages to achieve dependable wear-resistant coatings. The microstructure, phase composition, microhardness, and tribological properties of the HEA coatings were simultaneously investigated. TiAlZrVNiX coatings were composed of V-rich HCP solid solution phases, C14-Laves phases, and NiTi2 phases. The microhardness of the 1.5Ni coating measured 708.75HV0.3 and wear rate of 1.12 × 10−13m3N−1 m−1. The primary wear mechanism was abrasive wear, and it had been confirmed that the 1.5Ni coating exhibited best wear resistance. The Laves phase with high space utilization would produce precipitation strengthening and dispersion strengthening, effectively reducing the stress-induced microcrack diffusion. Additionally, the introduction of Ni elements induced the growth of the NiTi2 phase in order to enhance the strength while mitigating brittleness, thereby enhancing the wear resistance of the coatings.

Mechanically stable superhydrophobic surfaces constructed by laser surface texturing and micro-arc oxidation of TC4 alloy prepared based on SLM

In this paper, a superhydrophobic surface was prepared on the surface of Ti–6Al–4V (TC4) alloy prepared by selective laser melting (SLM), and the water contact angle (WCA) was 156.8°. The laser surface texturing (LST) and chemical modification treatments were combined with a micro-arc oxidation (MAO) treatment to improve the mechanical durability of the superhydrophobic surface. The surface morphology, wettability, wear resistance, and abrasion resistance of the composite coatings were analyzed, and the mechanism of abrasion resistance on superhydrophobic surfaces was discussed. The superhydrophobic surface that was prepared withstood abrasion under 600 # sandpaper at a pressure of 2.9 kPa and a movement distance of 1020 cm. In addition, the prepared superhydrophobic surface showed better wear resistance and friction reduction in friction experiment, exhibiting more stable coefficient of friction (COF) curve, lower COF value, and narrower abrasion marks. The results show that the prepared composite coatings not only exhibit superhydrophobicity, but also good mechanical stability, which effectively improves the mechanical property of superhydrophobic sample and significantly prolongs its service life in harsh environments. This study provided a new idea and preparation method for the preparation of mechanically stabilized superhydrophobic surface.

Effects of Cr and Mo content on the microstructure and properties of Fe-based amorphous composite coatings by laser cladding

In this study, we successfully produced Fe-based amorphous composite coatings on the surface of 45 steel using laser cladding technology, and the impact of the relative content of Cr and Mo elements on the microstructure, hardness, and wear resistance of composite coatings has been investigated. The results show that the microstructure of the coating changes from dendrite to amorphous nanocrystalline when the content of Cr and Mo is 20 and 15 wt. %, respectively. However, when the Mo element continues to be added, elemental segregation will be caused, resulting in a large number of brittle Fe–Cr–Mo intermetallic compounds and MoSi2 ceramic phases in the coating. Therefore, the appropriate element ratio can not only increase the amorphous phase content in the coating but also prevent elemental segregation. Among the three types of amorphous composite coatings studied, the Fe45Cr20Mo15B10Si10 (wt. %) composite coating exhibited the most favorable performance, primarily due to its highest amorphous content (43.33%). Through the interaction of the amorphous phase, α-Fe, Fe–Cr solid solution, and a small proportion of intermetallic compounds, this coating achieved a hardness of 1282.8 HV0.2, approximately five times that of the 45 steel substrate, and demonstrated superior wear resistance.