View of INVESTIGATION ON WEAR AND MICROSTRUCTURAL PROPERTY OF WC-12CO-CeO2 COATING DEPOSITED BY MICROWAVE CLADDING

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE INVESTIGATION ON WEAR AND MICROSTRUCTURAL PROPERTY OF WC-12CO-CeO2

COATING DEPOSITED BY MICROWAVE CLADDING

1Mohit Tiwari, Research Scholar,

2Prof. Pragyan Jain,

HOD, ME, GGITS Jabalpur, MP, India

3Prof. Tribhuwan Kishore Mishra,

Dept. of Mechanical Engineering, Gyan Ganga Institute of Technology and Science, Jabalpur

1. INTRODUCTION

There are many factors which directly influence the designing of machine and components some of the cost consideration, efficiency and maximum output, strength, rigidity and wear resistance. Wear is the damaging, gradual removal or deformation of material at solid surfaces. Causes of wear can be mechanical (e.g., erosion) or chemical (e.g., corrosion).Wear in machine elements, together with other processes such as fatigue and creep, causes functional surfaces to degrade, eventually leading to material failure or loss of functionality.

Thus, wear has large economic relevance. There are many methods to reduce the wear like by using lubrication, by increasing strength and hardness of surface and improving the surface properties by coating and cladding. The aim of this work is to increase the wear resistance, hardness and micro structural properties of the substrate by using microwave cladding.

1.1 Steel

Mild steel is widely used metal for industrial applications. it is available in the market easily and also available in the form of alloy and grades so it offer varied range of mechanical, physical and microstructure properties not available in other materials.

1.2 Wear

Wear define as an unwanted worsening of mechanical components through the detachment of material from the surface.

Wear degrades the life of components due to metal to metal contact, metal to abrasive particle contact and metal to erosive particle contact. Due to the replacement of the components and machine part running cost of machine

properties wear problems should be solved in place of developed the new material.

1.2.1 Types of wear

 1.2.1.1 Abrasive wear: Abrasive wear takes place when abrasive particles penetrate the softer surface of machine component.

According to ASTM (American Society for testing and material) When hard particles forced against sliding surface, soft surface losses the material in form of debries, Abrasive wear is found in most of the agriculture equipment where dust, soil and sand particles direct come to contact equipment and after some time replacement becomes necessary. Such type of wear not only increases the equipment cost but also increases the running cost of the machine.

Electrode deposition, hardening, and coating of hard metals are different technologies used to reduce abrasive wear. 5

 1.2.1.2 Adhesive wear: adhesive wear occurs when two bodies slide over or are pressed into each other, which promotes material transfer. This can be described as a plastic deformation of very small fragments within the surface layers. Adhesive wear responsible to increases the maintenance cost because due to continues contact between two metal surfaces week components wear out so replacement of such parts increases the running cost of the machine. Platting, hardening, induction hardening and surface coatings are used to reduce this wear. Railway wheel, bearing,

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE

 1.2.1.3 Erosive wear: Erosive wear can be defined as an extremely short sliding motion and is executed within a short time interval. Erosive wear is caused by the impact of particles of solid or liquid against the surface of an object. The affecting particles steadily expel material from the surface through rehashed miss actions and cutting activities. At the point when high-pressure fluid or gas strikes the outside of metal it evacuates the material because of cutting activity of particles..

Turbine blades exhaust fan in wooden industries facing this type of wear. Replacement of wear out blades is costly. So by using different moths like the coating of hard material increases the life and reduces the running coat.

 1.2.1.4 Corrosive Wear: Corrosive wear is defined as the damage caused by the synergistic attack of wear and corrosion when wear occurs in a corrosive environment.

Corrosive wear takes place due to the environmental effect and it slowly degrades the material properties. Due to contact between metal and salty environment near or on the sea removes the metal in the form of layer and finally, these equipment or machines have to be changed. Coating of WC, Niand Cr reduces such type of wear.

 1.2.1.5 Fatigue wear: Fatigue wear is a type of wear where the cyclic load is applied continuously on the surface to generate debris.

The fatigue process in metals may induce the generation of surface and subsurface cracks, which after a critical number of cycles results in severe damage, such as large fragments leaving the surface. This wear is most common wear in machine components. Surface hardening or hard material deposition decreases this wear.

2. LITERATURE REVIEW

1. Mr. Kanwar Jeet Singh et al (2016): Mr. Singh investigated the effect of coating of Ni based with &

without modifying by CeO2

deposited by microwave hybrid heating method P22 was used as a substrates in a 900 w and 2.45 GHz frequency microwave was used for 360 s. The cladding characterized by XRD, microstructure hardness and abrasive wear result indicated that CeO2 has helped in improving the hardness, wear resistance, microstructure, and 1% CeO2 shows best result.

2. Mr. Sunny Jafar et al (2015): Mr.

Jafar investigated the wear and frictional behavior of WC-12Co cladding which was deposited by microwave induced cladding at 2.45 GHz and 1.4 kw, XRD, SEM and wear behavior, were investigated. Result indicated that WC-12Co improve the wear resistance and microstructure of the specimen.

3. Mr. Dheeraj Gupta et al (2010):

Mr. Gupta had investigated the wear behaviour of WC10Co2Ni based coating/cladding which was deposited by microwave hybrid coating on austenitic MS (SS-316).

These cladding were characterize using through FESEM. As a result coating has good metallurgical bond with MS and no crack was seen in microstructure Coating which showed good wear resistance.

4. Mr. Ajit M Hebbale et al (2015):

Mr. Habbale had investigated the effect of Ni based cladding which was developed on high speed steel (SS304). The tests were accompanied in domestic microwave furnace with the help of Al2O3protect. The clad of wideness almost 1 mm, which was established by the experience of microwave at a frequency 2.45 GHz for 1080s. The established clad were tested using XRD, SEM and EDS and measurement of micro hardness. After the controlled dilution of element result of good metallurgical bonding of the molten particles with the substrate.

5. Mr. Apurbba Kumar Sharma et al (2012): Mr. Sharma investigated the carbide reinforced (tungsten

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE based) metal-matrix composite

cladding on austenitic stainless steel substrate which was deposited by microwave heating.

Cladding was developed by the help of microwave irradiation of the preplaced clad materials at 2045 GHz for 420 s. Results have shown that metallurgical bonding with substrate by partial dilution of materials. Clad has shown good stiffness and good adhesion in the presence of load.

6. Mr. Dheeraj Gupta et al (2012):

Investigation of Mr. Gupta show the effect of Ni bases cladding with cermet (WC10Co2Ni) powder on MS austenitic stainless steel SS- 316 surface. Domestic microwave of 900 watt and 45 GHz frequency was used to deposited the cladding with hybrid irradiation for 360 second time period. Results have shown that coating shows less porosity with minimum cracks which are less than one percent and micro hardens was 300H which is higher than a mass Substrate

7. Mr. Ashish Gaonkar (2017):

Investigated the effect of WC-12Co cladding on nickel-based Super Alloy (Grade IN738) by the help of microwave hybrid heating method.

The thickness of the clad was maintained throughout the surface approximately 500 micron this cladding was characterized by using SEM, EDS. Coating resulted in good metallurgical bond and fine microstructure.

8. Mr. Sarbjeet Kaushal et al (2015): Investigating the micro structural and mechanical properties of nickel based cladding with 10% SiC powder as reinforced deposited by microwave hybrid heating on SS-420 steel substrate.

Mr. Kaushal by the help of Domestic microwave of frequency 2.45 GHz and 900 W was used to deposited the cladding. He was

able to give results which indicated that good metallurgical bond between cladding powder and MS surface, different phase were identified on XRD. Cladding increases the hardness upto 652 ± 90 HV.

3. PURPOSE OF THE PROJECT

The phenomenon of material removal is common and is found on most of the agriculture and automobile machine components, when these components come to contact with hard abrasive particles wear takes place and finally components is to be replaced due to component failure. These replacement of components increases the running cost and labour cost. In agricultural sector when machine come in direct contact either in dry or wet condition than due to sand and stone abrasion and scratching actions takes place these degrade the components quality.

Mild steel is widely used in India for agriculture equipment and automobile machinery. Coating improved the life of components. Coating deposition is costly process. HVOF(high velocity oxy-fuel) coating and Plasma thermally sprayed coating are highly expensive and coating equipment is not portable. The aim of this work to used microwave hybrid cladding to deposit WC-12Co- CeO2 powder on MS surface for increasing the wear resistance of working surface.

4. METHODOLOGY

The aim of this section is to explain experimental steps including, microwave setup sample preparation and characterization of cladding.

4.1 Sample Preparation

MS steel use for cladding and 1020 grade steel sheet purchased from Nextgen steel

& alloys Mumbai. Finally samples of dimensions 15mm×15mm×10mm were prepared by using hacksaw blade, hydraulic hexsaw, bench grinder and surface grinder.

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Figure 1. (a-d) Sample preparation 4.2 Coating Powder Selection

For cladding WC-12Co was selected then this powder was farther modified with addition of 1%CeO2,2%CeO2 and 3%CeO2. Finally W-12C0-0 CeO2, W- 12C0-1 CeO2, W-12C0-2 CeO2 and W- 12C0-3CeO2 powder combination were prepared for deposition of cladding. WC- 12 Co powder was purchased from MECPL, Jodhpur (India) and CeO2 powder purchased from Qualikems PVT Vadodara (India).

4.3 Development of Cladding

Domestic microwave (LGmake) with frequency -2.45 GHz and power 900 W ( specifications are shown in Table No-1) was apply for cladding on MS surface.

Skin depth is significant factor to deposition the microwave cladding and radiation emitted by microwave cannot react directly surface at room temperature. Since metal reflect the radiation concern with skin depth.

Critical temperature plays important role to increase the skin depth. Hybrid heating

is necessary to achieve critical temperature. In microwave hybrid heating charcoal is used as a susceptor which absorbs microwave radiation at normal temperature and get heated very fast manner so temperature reached at critical temperature.

In order to separate the metal and charcoal powder separator (graphite plate) was used. Radiation and convection heat transfer mode transfers the heat.

Temperature increases layer to layer finally temperature becomes equal then temperature equal to melting point and metal powder starts defuses on metal.

Refractory brick was utilized to maintain a strategic distance from direct contact to the occurrence radiation of microwave.

Cladding powder was preheated tat 150°

Ctoeliminatewetness, unstable element.

Powder was dispersed up to 2 mm on metal through the experiment Refractory bricks box was used to make this arrangement. These re-factory bricks was purchased from surya industries, which is situated near about Jabalpur.

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Figure 2 Microwave Experimental Setup of Cladding 5. RESULT ANALYSIS

5.1 SEM (Microstructure) Analysis

Figure 3 SEM images of WC-12C0-0CeO2, WC-12C0-1CeO2, WC-12C0-2CeO2, and WC- 12C0-3CeO2 Cladding

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE Fig .3(a-d) shows the Scanning Electron

Microscopy (SEM) result of the cladded sample i.e. WC-12Co-0CeO2, WC-12Co- 1CeO2, WC-12Co-2CeO2 andWC-12Co- 3CeO2 cladding. WC-12Co-0CeO2 shows pores structure, some cavities and micro cracks are seen in WC-12Co-0CeO2 cladding. As CeO2 content increases, dense and refine microstructure were observed in cladding. WC-12Co-2CeO2 and WC-12Co-3CeO2 shows more refine structure. Rey region shows the presence of cobalt and bright region shows the presence of tungsten. Dendritic structure developed during cladding.

Ordination of new boundaries were clear seen in microstructure. Detrick CeO2 prevents the boundary distortion and deposited outside the periphery of tungsten along with cobalt binder.

Therefore WC-12Co-2CeO2 and WC- 12Co-3CeO2 shows dense and refine along with minimum pores. But some pores and cavities are seen in WC-12Co- 3CeO2. The reason of this phenomenon is due to excess amount of CeO2 does not absorbed by matrix and after optimum addition of CeO2 in WC-12Co-2CeO2 is not significant and this result can be attribute to wear test.

5.2Three- D Morphology

Figure 4 Three- D Morphology of WC-12C0-0CeO2,WC-12C0-1CeO2, WC-12C0-0CeO2, and WC-12C0-3CeO2 Cladding

Fig.4 (a-d) shows the 3-D morphology of WC-12Co-0CeO2, WC-12Co-1CeO2, WC- 12Co-2CeO2 andWC-12Co-3CeO2

cladding. WC-12Co-0CeO2, cladding shows the dense and homogeneous microstructure along with refine

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE boundary. Where’s some pores and micro

cracks are visible in WC-12Co-0CeO2 and WC-12Co-3CeO2 cladding. Result indicated that higher percentage of cerium oxide increased boundary segregation which causes higher wear rate.

5.3 XRD Pattern

XRD patter of cladding is shown in fig.5.

Strong peak of WC and minor peak of Co

was observed in XRD patter. Minor peak of W2C, was also seen. It may be due to low degree of composition of WC to W2C during spraying. But presence of W2C does not affect the wear behaviour. This phenomenon shows that chromium carbide is properly distributed in WC-Co matrix. Presence of CeO2also seen in CeO2 Modified cladding.

Figure 5 XRD Pattern of Coating 5.4Microhardness

Fig.5 shows the micro-hardness WC- 12Co-0CeO2, WC-12Co-1CeO2, WC- 12Co-2CeO2 andWC-12Co-3CeO2 cladding. Result indicated that addition of CeO2 significantly improve the hardness up to 2 % of CeO2 after this hardness starts reduce. It may be due the addition of extra CeO2 after optimum range increases the brittleness of sample result

as in increasing of micro cracks and voids. WC-12CO-2CeO2claded sample shows 15% higher hardness as compared WC-12CO-0CeO2specimen where WC-

12CO-3CeO2 and WC-12CO-

1CeO2cladding shows13% and 3% higher hardness respectively to WC-12CO- 0CeO2cladding. Result clear indicated that WC-12CO-2CeO2showes maximum hardness.

Table 1 Hardness

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Figure 6 Microhardness 5.5 Porosity

Fig.6 shows the threshhold image of WC- 12Co-0CeO2, WC-12Co-1CeO2, WC- 12Co-2CeO2 andWC-12Co-3CeO2 cladding. ImageJ software was used to calculate porosity (Fig. 6) on the basis of percentage area calculation convert. 2-D SEM images was selected then converted in to 8 Bit images after this proper scale was chosen then threshold selected to

find out the porosity. Result indicated that WC-12CO-2CeO2showes minium porosity as 5.5% where other cladding WC-12CO-3CeO2, WC-12CO-1CeO2 and WC-12CO-0CeO2 showes 10%, 7% and 11% respectevely. WC-12CO-2CeO2 cladding showes best result and influences the wear result. Porosity of cladding shown in taable no.3.

Figure 7 Threshold Image

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE Table 2 Porosity

Figure 8 Porosity 5.6 Wear (Weight Loss)

Fig.8 shows mass loss ofWC-12Co-0CeO2, WC-12Co-1CeO2, WC-12Co-2CeO2 andWC-12Co-3CeO2 cladding. It was found that material removal ratio is lower in WC-12Co-2CeO2 cladding. because of define and dense microstructure. Where’s WC-12Co-0CeO2 cladding shows higher wear due to high cutting action and more plastic deformation. WC-12Co-0CeO2,

WC-12Co-1CeO2, andWC-12Co-3CeO2 cladding shows 1.8,1.5 and 1.3 times higher mass loss as compared to WC- 12Co-2CeO2cladding. Result indicated that WC-12Co-2CeO2cladding provided better wear resistance. Optimum addition of 2% CeO2showed the best result and maximum wear resistance. Weight loss of the cladding shown in table no.3 Table 3 weight Loss

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Figure 9 Wear (weight Loss) 5.7 Worn Out Surface Alalysis

Figure 10 Wear out surface Fig.10 shows the wear out worn surface

ofWC-12Co-0CeO2, WC-12Co-1CeO2, WC-12Co-2CeO2 andWC-12Co-3CeO2 cladding. Deep and wide groove seen in WC-12CO-0CeO2 and WC-12CO-3CeO2

xladding, small gove was seen in WC- 12CO-1CeO2 coating. Ploughing and cutting dominate the wear mechanisum and responsible for remuwal of metal.

Tribooxide laye clear seen in WC-12CO-

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Vol.04, Issue 12, December 2019, Available Online: www.ajeee.co.in/index.php/AJEEE 2CeO2 cladding which prevents the wear

so WC-12CO-2CeO2 shows the minimum wear as compared to another cladding.

Very small groove Very small groove seen in this clading and due higher hardnes casuse the minimum wear. In higher amount of CeO2 increases the britlness may be increases the wear.

6. CONCLUSION

1. WC-12Co-2CeO2 and WC-12Co- 3CeO2 shows more refine structure. Detrick CeO2 prevents the boundary distortion and deposited outside the periphery of tungsten along with cobalt binder.

2. XRD patter of cladding shows strong peak of WC and minor peak of Co was along with minor peak of W2C.

3. WC-12CO-2CeO2showes

maximum hardness. WC-12CO- 2CeO2 claded sample shows 15%

higher hardness as compared WC- 12CO-0CeO2.

4. The WC-12CO-2CeO2showes minium porosity as 5.5% where other cladding WC-12CO- 3CeO2,WC-12CO-1CeO2 and WC- 12CO-0CeO2 showes 10%, 7% and 11% respectevely.

5. Optimum addition of 2%

CeO2showed the best result and maximum wear resistance.

6. Ploughing and cutting dominate the wear mechanisum and responsible for remuwal of metal.

Tribooxide laye clear seen in WC- 12CO-2CeO2 cladding which prevents the wear.

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