REVIEW PAPER ON WEAR PROPERTY OF NI-WC COMPOSITE COATINGS Vipin Kumar Kachhi, Tribhuwan Kishor Mishra, Sandeep Kumar Dubey
Department of Mechanical Engineering, Gyan Ganga Institute of Technology and Sciences Abstract - An experimental study followed by a comparative study of HVOF sprayed NI- 0WC, Ni-5WC, NI-12.5WC, and NI-25WC coatings were performed at three different loads of 20, 40, and 60 N. Two-body, abrasive wear of coated specimens against silicon carbide abrasive, was performed as per the G 99–5 standard at room temperature. SEM and XRD were used to characterize the coating for microstructural and phase study. The experimental results suggest that the NI-12.5WC coating exhibited higher abrasive wear resistance due to dense microstructure. Ni-0WC, Ni-25WC, and NI-50WC shows 83%, 33%
& 86%, 86.6%, 50% & 130% and 70% 45% & 109% higher wear rate than Ni-12.5WC coating at 20, 40 and 60 N applied load respectively Cutting wear mechanisms were seen in Ni-12.5WC coating, where NI-0WC and Ni-50WC showed fracture wear mechanisms.
1 INTRODUCTION
Steel is a widely used material for engineering applications because of its availability in the market. The available alloys and steel grades provide a wide range of properties not found in any other family of materials. Carbon and other alloying elements existing in steel significantly affect the mechanical, microstructure, and tribological properties. A further comprehensive variety of thermal spraying could be accepted to vary these materials' microstructure and mechanical &
tribological properties.
Economic facets play an essential role in the selection of material. As a result, hard material is necessary with which is the cheapest and most readily available. In industries, most of the production work is done on medium carbon and low carbon steel. Due to the addition of alloy, the cost of steel rises, mild steel offers a solution to this problem because the price of mild steel is meager compared to other alloy steel. Proper material range should be selected only after carefully considering part design, wear mode, material, and environmental interactions.
Mild steels are the best raw material choice when high pressure and loads are applied, increasing wear. Their strength after HVOF hardening meets the demanding requirements of wear- resistant steel. When the HVOF technique is used to coat the NI-WC powder, it increases the density and hardness of steel to a great extent. Typical mild steel applications are manufacturing road and
agricultural machinery blades, track segments for forestry machines, snow plough wear plate, crushers, and other process machinery. All types of machine parts require high strength. It is also used in an automobile to make the vehicle body and chassis. Mild steels can be operated in both hot and cold conditions. The shaping and joining of mild steel can be quickly expert using standard workshop methods. The low alloy and impurity contents of mild steel making them resistant to hot cracking. Mild steels are also very suitable for surface hardening.
Thus, there is a need to examine the effect of powder coating on steels' mechanical and tribological behaviors. The creation of mild steel was not an overnight development. It took engineers and scientists many years to perfect the right formula as well as structural security.
1.1 Wear of Material
Wear is usually defined as the unwanted deterioration of an element by excluding material from its surface. It occurs by displacement and detachment of particles from the surface. For example, the mechanical and wear properties of steel are abruptly reduced due to wear. Wea takes place due to the friction of metals against other metals or each other, erosion due to gases, liquid, rubbing of solid particles from the surface, and other surface phenomena. Wear is measured in the laboratory by weight loss in material, and wear resistance is described by the weight loss per unit area per unit time.
There are the following standard types of wear as defined below.
1.2 Surface Modification by Coatings and Surface Treatments
Principal machine elements such as rolling-contact bearings, gears, cams, traction drives, and tappets are required to run occasionally under severe environmental and tribological constraints. These environments include high corrosion environments surface speed, high working temperatures, and high load circumstances. Thus the surface failure such as pitting or spalling/flaking occurs. Surface modification improves the rolling contact, fatigue strength of contact machine elements, not only various three. There are various surface modification techniques such as thermal spraying, physical vapor deposition, chemical vapor deposition, and electrochemical deposition: surface hardening processing or surface treatment technologies such as induction hardening, flame hardening, etc. Although selecting the optimal surface modification treatment according to usage is tough, some techniques reduce friction and wear.
Consequently, the rolling contact fatigue life is improved. As a result, coatings are wear-resisting materials.
They can be classified as hard coatings that exhibit Moderate variance but shallow wear and soft coatings that exhibit relatively low friction but relatively high wear. A brief description of some essential hard and soft coatings is Given below.
2 REVIEW OF LITERATURE
Thakur et al. (2013) Investigated wear properties of WC-Co-Cr coatings. HVOF method was used to deposit the coating.
SEM and XRD evaluated microstructural properties. Sliding wear and abrasive wear were tested using a pin on the disc tribometer. The result indicated that the Nano coating of WC shows maximum hardness and wear resistance. In addition, a plastic deformation mechanism was reported during abrasive wear.
Ma et al. (2014) Investigated wear properties using different grain sizes of powder for coating. Phase and the microstructural study were done using XRD and SEM. The result indicated that bimodal coating exhibits maximum hardness and toughness. It also shows
maximum wear resistance as compared to sub-micron and nano-coatings.
Gisario et al. (2015) used an HVOF method to coating deposition to WC-12Co powder, and after this, laser post-treatment was done. The coating was deposited on cylindrical AA- 6082 T6 aluminum alloy. XRD and SEM were used to characterized the coatings. The result showed that laser post-processing enhancing the homogenously on a matrix and decreases the grain size of carbide particles.
Zafar et al. (2016) used WC- 12Co powder to deposit the coating on the steel. HVOF method was used for coating deposition, and after that, heat treatment of deposits was done in argon control atmosphere. Some new phase including amorphous Co6W6C, Co3W3C were made, which are amorphous, and the decrease of WC and W2C phases were also noticed
Fu et al. (2016) Investigated the hardness, porosity, and toughness of od WC-12 Co coating deposited by the high- velocity oxy-fuel method. The author reported decomposition of the coating along with three different zones with less low and adequate decarburization. The decarburization process is explained in detail. Hight heat addition and oxygen promote decarburization, and finally, W2C phase is formed.
Vashishtha et al. (2017) Used three different coating powders WC-12Co, WC-10Co-4Cr, and Cr3C2-25NiCr, to deposit the coatings by the HVOF coating technique. Abrasive wear, hardness, and toughness of the coatings were tested and discussed. Microstructural and phase study was carried out using SEM and XRD. Silicon carbide abrasive media carried the abrasive test for abrasive wear test, and silica sand was used for erosion test. The author reported that WC_112Co coating exhibited higher hardness abrasive and erosion wear resistance. Wear increases with increasing load plugging and cutting where magnesium was detected wherein Cr3C2-25NiCr coating.
Bang et al. (2018) HVOF coating method was used to deposit the WC-12Co coating. XRD and SEM study was done for phase identification and microstructural analysis. For mechanical and physical properties, hardness, porosity, and toughness were also
investigated. It was reported the presence of Co6W6C, Co, W, and W2C formed during deposition. The wear test was also investigated and increases with sliding distance.
Mishra et al. (2018) Used WC- 12Co and WC-10Co-4Cr coating powder to deposit the coating. The sliding test was done using a pin on the disc wear tester using EN 32 disc as a counter body. SEM and XRD were also evaluated to study the microstructure. Negative wear trends were reported initially due to less hardness of the counter body.
Transfer layer was formed during sliding action due to sliding movement.
Gao et al. (2019) used the HVOF coating method to deposit WC- nano (WC- Co) coatings iron substrate. Wear behavior and coefficient of friction were investigated using a block-on-ring wear tester. The author suggested that the WC- nano (WC-Co) coatings exhibited higher hardness, lower wear rate, and higher coefficient of friction than micro-sized and nano-sized WC-Co coating.
Fu et al. (2020) studied the variation of Ni contents (5, 15, 25, and 75 wt. %) on wear and mechanical properties of WC coatings. SRD, SEM, microhardness, and fracture toughness test was also evaluated. A pin-on-disc wear test was used for the abrasive test with alumina abrasive paper as a counter material. The addition of Ni improved the adhesion between substrate and coatings.
Low porosity, higher hardness, higher toughness, improved wear resistance was reported with Ni added coatings. It was also reported that the addition of Ni minimizes the decarburization [63].
Eitvydas Gruzdy et al. (2008) reported that Coatings formed by flame spraying using Ni, Cr, B, Si, and W.C./Co powders are suitable for surface protection because of their exclusive properties. These properties can be altered according to specific situations of application. The results show that though there are no significant changes in macro hardness, the best wear resistance is demonstrated by coatings containing about 25 % W.C./Co. Further increase in W.C./Co percentage increases the risk of carbide particles being removed from the surface due to the decreased cohesion.
M.w. Richert et al. (2011) reported that the High-Velocity Oxy-Fuel
sprayed coats show more uniform and fine-grained microstructure than plasma- sprayed coats. The microhardness of WC- Co carbide coats placed above 1000 HV and chromium carbide coats below 1000 HV. The wear-resistant strongly depends on the internal microstructure of coatings. The nanometric features contribute to the increase of surface smoothness of layers and increase the resistance against wear.
J. Rodr´ıguez et al. (2003) reported that Ni Cr B Si alloys, deposited by thermally spraying techniques, maintain their wear-resistant performances up to bulk temperatures of 500 ◦C. The spraying process is a significant factor in the Ni Cr B Si alloys' wear behavior. The alloys deposited by flame spraying with fusion have better wear resistance than those deposited by plasma spraying. Load is much more influential than the temperature within the ranges analyses. The presence of tungsten carbide in the powders is not a beneficial factor on the wear performance of thermally spraying Ni Cr B Si coatings.,
M. Hadada et al. (2007) reported that adhesion and wear behavior of cermet and different intermediate coatings within sandwich structured based cermet coatings were studied in this work.
Cermet, combinations with Ni–Cr 80–
20HVOF deposited and Ni-plating electrochemically deposited layer showed high adhesive strength value. The blasted interface of Ni-plating-X did not deliver a higher adhesion value rather a difference in wear performance.
S. Harsha et al. (2008) reported that Loss of material from the wear surface of the coating takes place primarily by removal of soft matrix materials followed by fragmentation of hard carbide particles as scanning electron microscopic study exhibited deep abrasive marks only in eutectic matrix
Y. Perez Delgado et al. (2011) reported that reciprocating and rotating wear testing of WC 10wt%Co cemented carbide surface finished by sequential wire-EDM or polishing in dry sliding contact with WC-6wt%Co counter body revealed a significant increase of friction coefficient and wear level by wire-EDM.
However, substantial improvements were obtained with finer-executed EDM finishing steps. Differences in tribological
behavior can be attributed to the wire- EDM induced recast layer, exhibiting lower wear resistance than the polished surface. In addition, the higher friction coefficient and wear volume were encountered in rotating sliding contact than linearly reciprocating conditions, which are believed to involve more vital interaction between wear debris at the sliding contact interface. The nature of the compound layer in the wear track and wear particles must be further elucidated by a thorough investigation of cross- sectioned wear tracks.
Shan-ping lu et al. (2003) reported that the cobalt coated on WC particles dissolved into the Ni–Cr–B–Si alloy during the brazing process, which decreased the hardness and wear resistance of the coating. The brazed composite layer showed different wear behaviors under other wear conditions. In the high-speed rotating slurry erosive wear, the WC reinforcement provided good protection to the Ni–Cr–B–Si–(Co) matrix.
In the wet sand/rubber wheel abrasive wear, the primary wear mechanism was controlled by the scratching and micro- cutting of the matrix, followed by the pull- out of WC particles. The wear resistance of the brazed coating was superior to that of the flame overlaid in both the slurry and the abrasive wear tests.
AJ Horlock et al. (2002) reported that employed alumina produced significantly greater wear rates than silica abradant under the abrasive wear conditions. This is due to two factors, namely differences in abradant morphology and hardness. When tested with alumina, the coatings produced in the present study performed better in abrasive wear than conventional nickel/
chromium–chromium carbide HVOF- coatings. However, when tested with silica, their performance was comparable to that of the best coatings from commercially available powder. This can be attributed to the high hardness of TiB2 particles, well bonded to the nickel-rich matrix, which contains a proportion of amorphous/nanocrystalline structure.
K. Van Acker et al. (2005) reported that the influence on the resistance against mild three-body abrasion of small SiC in the ball cratering test is less pronounced. There is some decrease in wear coefficient with
increasing carbide concentration, but the wear of the matrix seems to play the most critical role. It is shown in an experiment with a dilute abrasive slurry that the mixture of wear-resistant carbides and minor wear resistant matrix promotes the rolling wear, wherein a pure matrix material the wear mode already changed to grooving type wear. The wc particles are dispersed homogeneously in the matrix, and apparent particles clustering is not detected. Only some fine carbides are prone to clustering, derived from the precipitation of compound carbides, but the coarse particles almost isolate each other.
P. Wu et al. (2004) reported that the microscopic morphology and distribution of WC particles in laser-clad Ni–WC coatings were investigated using SEM. The processing parameters and WC particles compositions are significant during the laser cladding and should be optimized to get the high-quality coating free of pores and cracks. The experimental results showed that there were two effective methods to avoid the stress concentration and gaps. The three- step laser-clad gradient coating with WC complex phase varied gradually from the substrate to the top and the 60% WC composite coating with a marked gradient distribution at the interface between WC and the matrix; both were high-quality coatings to avoid the stress concentration.
However, the three-step laser processing is too complicated to be completed quickly, which is not recommended for wear resistance application, especially for long-term abrasion. Thus a high-quality coating without porosity or cracking was obtained using the optimized WC particles compositions and laser parameters under one-step processing.
E. Fern Mendez et al. (2005) reported that the microstructure consists of a matrix phase of a solid solution of Ni, Cr, and Fe forming a dendritic structure with an interdendritic lamellar eutectic phase made up mainly of Ni and Si and Cr-rich precipitates concentrated mainly at the overlap zones. A minor influence of sliding speed on wear was observed in the dry sliding block-on-ring wear tests that were carried out, except at a rate of 0.65 m/s, when wear was markedly lower because of a near-continuous layer of rust between the surfaces that were in contact.
This process of wear by oxidation is maintained under all test conditions and is accompanied by the mechanism of adhesive wear at the highest loads tested.
Chun Guo et al. (2012) reported that NiCrBSi coating and different WC–Ni contents of NiCrBSi/W.C.–Ni composite coatings were produced on stainless steel by laser cladding. The effect of WC–Ni added on the microstructure, composition, microhardness, and tribological properties of the laser cladding Ni-based alloys coatings under different wear conditions were investigated. It has been found that the WC–Ni added in the laser cladding coatings contribute to greatly increase the micro hardness and wear resistance of the Ni-based alloy coating, which is attributed to the formation of hard WC phase and a partial dissolution of WC particles on the Ni matrix after laser cladding. The laser cladding NiCrBSi and different WC–Ni contents of NiCrBSi/W.C.–Ni composite coatings were experiencing only mild abrasive and adhesive wear when sliding against the AISI-52100 steel ball and ring counterpart.
A. Hidouci et al. (2000) reported that The higher hardness of the cobalt- base alloy coatings compared to the nickel-base alloy coatings is attributed to the presence of M7C3 type carbides (mainly chro-mium-rich carbides) dispersed in the c-(Co) phase matrix. The lower hardness of the Ni-base alloy coatings is related to the presence of a c- (Ni, Fe) solid solution and low concentrations of chromium and carbon.
The nickel-base alloy matrix of the coating is ductile: deformations of up to 50% are achieved, with only a few cracks, and hardness values higher than 450 HV are measured. Analysis of the hardening phenomenon occurring during plastic deformation is in progress.
JM miguel et al. (2003) reported that As sprayed coatings suffer dissolution during the thermal spraying that may produce a decrease of their tribological properties Plasma sprayed NiCrBSi shows the worst sliding wear resistance. The analysis of debris and wear track indicates that splat de lamination is the main wear mechanism.
This wear mechanism produces debris composed by large flake-like particles and
big cavities of similar size in the wear track. Spray & fused coating has the best sliding wear resistance (similar to the HVOF sprayed NiCrBSi). The main wear mechanism is adhesion, but abrasion and de lamination also take place. The fatigue wear process (inter splat de lamination) in the HVOF sprayed coating is not so important as in the plasma sprayed coating due to the best mechanical bonding among splats.
C. Navas et al. (2006) reported that Comparison of the microstructure of the laser clad and the flame melted reveals a similar phase composition in both coating, but different distribution, morphology and size of phases. LC shows a heterogeneous distribution of different size phases across the Ni solid solution as the SFM exhibits similar size phases homogenously distributed. Despite these micro structural differences, both coating showed analogous wear behavior, which, critically, depended on the tribological conditions used. Under abrasion wear conditions, the morphology of the abrasive particles influences strongly the wear rate and wear mode of the coatings.
Despite the higher hardness of the diamond particles in comparison with the SiC particles, the highest wear rate was obtained with the SiC slurry, due to its extremely sharp shape Comparison of the microstructure of the laser clad and the flame melted reveals a similar phase composition in both coating, but different distribution, morphology and size of phases. LC shows a heterogeneous distribution of different size phases across the Ni solid solution as the SFM exhibits similar size phases homogenously distributed. Despite these micro structural differences, both coating showed analogous wear behavior, which, critically, depended on the tribological conditions used. Under abrasion wear conditions, the morphology of the abrasive particles influences strongly the wear rate and wear mode of the coatings.
Despite the higher hardness of the diamond particles in comparison with the Si C particles, the highest wear rate was obtained with the Si C slurry, due to its extremely sharp shape In this work, the influence of the microstructure on the wear response of a material, under a given set of working conditions, has been shown. The knowledge of the co-relations
between processing conditions, metallurgical and mechanical properties and wear behavior, is essential for the design and selection of any tribological system.
MF Buchely et al. (2005) reported that Three-layer complex carbide deposits showed the best abrasive wear resistance of all the tested hard facing alloys.
Nevertheless, when only one layer was deposited the high dilution levels changed the microstructure and strongly reduced the wear resistance. W-rich hard facing alloys showed a very good abrasive wear resistance with only one layer, due to their unique combination of tough M6C and hard, massive MC carbides in a eutectic matrix. M7C3 carbides played a crucial role in the abrasive wear resistance of all the deposits studied, since they act as effective barriers to cutting and ploughing by abrasive particles. The main mass removal mechanisms identified after examination of the worn surfaces were micro-cutting, ploughing and brittle fracture of carbides.
Plastic deformation was also significant, especially in eutectic microstructures.
Eitvydas Gruzdys et al. (2009) reported that a number of coatings were deposited on steel substrates by flame spraying using powder with different W.C./Co concentrations (0 %, 15 %, 20
%, 25 %, 30 %, 45 %). Coatings formed by flame spraying using NiCrBSi and W.C./Co powders are suitable for surface protection because of their exclusive properties. These properties can be altered according to specific situation of application. The results show that though there are no significant changes in macro hardness, and the best wear resistance is demonstrated by coatings which contain about 25 % W.C./Co. Further increase in W.C./Co percentage increases risk of carbide particles being removed from the surface due to the decreased cohesion.
Al. Mickiewicza et al. (2011) reported that The High Velocity Oxy-Fuel sprayed coats show more uniform and fine grained microstructure than plasma sprayed coats. The micro hardness of WC- Co carbide coats placed above 1000 HV, and chromium carbide coats below 1000 HV. The wear resistant strongly depends on the internal microstructure of coatings. The nano metric features contribute to the increase of surface
smoothness of coatings and increase the resistance against the wear.
2.1 Need of Present Work
In agriculture and automobile machines, wear is responsible for damaging the surface and is also responsible for reducing the component life. When agriculture machines come in direct contact with hard abrasive particles, surface failure occurs due to wear. This causes severe problems and affects the cost of replacement, and increases the labor cost and downtime. So the main aim of W.C./Ni-based coating and its impact against the wear resistance tribology and microstructure properties.
Agriculture supports the economy for most developing nations, including India, and source of income for more than 60% of their population. Even though the mechanization of agriculture helps in reducing human drudgery and raising grain productivity, the level of mechanization in these countries is still at a deficient level. The main reason for this is the non-availability of high-quality implements and lack of demonstrated services for their population.
Mechanization does not mean only the agro-machines operated by power, but also the implements run by animals and men. Most commonly used farm implements are ploughs, harrows, cultivators, peddlers, furrow opener, therapy, kundalini, etc. Indian agro- industries and village artisans usually use cheaply and abundantly available low carbon and mild steels to manufacture these farm implements to suit every farmer, either rich or poor. During agricultural operations (either dry or wet ), the farm implements undergo abrasion by scratching the sand and stone particles in the soil. It is the most common cause of their quick failure and damage. It is, therefore, necessary to minimize wear. Due to limited resources and unavailability of economically feasible technology, agro-industries have not improved these steels' mechanical properties and wear resistance substantially. Researchers have attempted to improve the wear resistance of steel materials, but very little attention has been paid to reducing the wear of farm implements materials. Thus, there is an urgent need to substantially upgrade
low carbon and mild steels' mechanical properties and wear resistance in actual soil conditions. The present work aims to improve mild steel's wear resistance and mechanical properties by developing an economically feasible carburization technique. Also, the current work is applicable not only for the farm implements but also for the applications like material of automobiles, machines, gears, springs and high strength wires etc.
3. CONCLUSION
The conclusions drawn from the tests have been discussed below
1. Ni-WC powder possesses a spherical shape which helps to increase the flowability of powder during spraying.
2. Ni-12.5WC coating shows a dense microstructure with good bonding between surface and carbide particles.
3. Some micro-cracks and porosity were observed in NI-25 WC coatings, and it drastically increases in NI- 25WC coating.
4. Ni-0WC, Ni-25WC, and NI-50WC shows 83%, 33% & 86%, 86.6%, 50% & 130% and 70% 45% & 109%
higher wear rate than Ni-12.5WC coating at 20, 40 and 60 N applied load respectively.
5. Cutting wear mechanisms were seen in Ni-12.5WC coating, where NI- 0WC and Ni-50WC showed fracture wear mechanisms.
6. The wear (weight loss) increases with an increase in load for all the coatings
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