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Wear Behaviour of Recycled Hard Particle Reinforced NiCrBSi Hardfacings Deposited by Plasma Transferred Arc (PTA) Process

Key Engineering Materials

November 2012
527:179-184

DOI:10.4028/www.scientific.net/KEM.527.179

Authors:

Arkadi Zikin

Nutech GmbH

Irina Hussainova

Tallinn University of Technology

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The main goal of present work was to study room temperature wear behaviour of advanced cermet particle reinforced hardfacings. For this purpose three different recycled powders: WC-Co, TiC-NiMo and Cr3C2-Ni were used as reinforcements for the commercially used NiCrBSi matrix alloy. Plasma transferred arc hardfacing process was used for deposition of the hardfacings. Manufactured hardfacings show only average wear resistance compared to WC/W2C reinforced NiCrBSi hardfacing with two times higher wear values. However, in combined impact/abrasive and erosive contacts, manufactured hard particle reinforced hardfacings have shown very promising results with high wear resistance. It was shown, that double structuring along with right material constituent and coating procedure selection may provide high wear resistance. © (2013) Trans Tech Publications.

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Wear behaviour of recycled hard particle reinforced NiCrBSi

hardfacings deposited by plasma transferred arc (PTA) process

A. Zikin

1,2,a

, I. Hussainova

, C. Katsich

, P. Kulu

and D. Goljandin

AC2T research GmbH, Viktor-Kaplan-Straße 2, 2700 Wiener Neustadt, Austria

Department of Materials Engineering, Tallinn University of Technology, Ehitajate tee 5, 19086

Tallinn, Estonia

zikin@ac2t.at,

irhus@staff.ttu.ee,

katsich@ac2t.at,

priit.kulu@ttu.ee,

dmitri.goljandin@ttu.ee

Keywords: abrasive wear, erosive wear, impact wear, cermet, hardfacing

Abstract.              



 !



  $%

&'

!         (

 

$%)(

          

     *         





Introduction



        



+ 

(         &  

    *          

  ,(           

     -.#/ *(    

&    0    1    

-"2/



3         )  

4'+5 

!&

4!!5       &      

-67/)1

  1  1         



           

-8.9/ %            

-.9/

+       '+     

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Key Engineering Materials Online: 2012-11-12

ISSN: 1662-9795, Vol. 527, pp 179-184

doi:10.4028/www.scientific.net/KEM.527.179

Tech Publications Ltd, www.scientific.net. (Research Gate for subscription journals-09/02/24,20:45:02)

OPTIMIZATION OF HARDMETAL REINFORCEMENT CONTENT IN Fe-BASED HARDFACINGS FOR ABRASIVE-IMPACT WEAR CONDITIONS

Conference Paper

Full-text available

Mar 2016

The aim of the present research is to determine the optimal hardmetal reinforcement content for Fe-based self-fluxing alloy matrix hardfacings for use under abrasive-impact wear conditions. Hardfacings with hardmetal contents of 20, 40, 60, and 80 wt% are produced from disintegrator-milled unsorted hardmetal scrap and commercial Fe–Cr–Si–B self-fluxing alloy powder by liquid-phase sintering in vacuum. The microstructure of the hardfacings is studied by optical microscopy and their porosity is determined. The Rockwell A hardness (HRA) is measured at their surfaces. The hardfacings are subjected to an abrasive-impact wear test (with granite gravel abrasive at a velocity of 80 m/s and an impact angle of 90º); the reference material is an abrasion-resistant steel, Hardox 400. From the test, the volumetric wear of the hardfacings is determined, and wear mechanisms are studied by scanning electron microscopy. The hardfacing with 40 wt% hardmetal reinforcement shows the least wear (0.3 times the wear of the reference material), whereas that with 80 wt% hardmetal reinforcement shows the greatest wear (2.9 times the wear of the reference material). During the wear process, surface fatigue wear of the matrix first occurs, followed by loss of loose reinforcement. With increasing hardmetal content, the ductility of the matrix is reduced and residual tensile stresses are increased, leading to greater wear.

Structure, Phase Composition, and Wear Mechanisms of Plasma-Sprayed NiCrSiB–20 wt.% TiB2 Coating

Article

Full-text available

Mar 2015

The structure, phase composition, and wear mechanisms of plasma-sprayed NKhTB20 coating (NiCrSiB–20 wt.% TiB 2) are studied. To produce NKhTB20 composite powder, commercial PR-NKh16SR3 (NiCrSiB) powder was mixed with 20 wt.% TiB 2 and the charge was pressed and sintered in vacuum at 1100C for 30 min. During sintering, the components react to form chromium borides. The sinters were ground and classified into the particle size fraction –100+60 nm for plasma spraying. The plasma-sprayed NKhTB20 coating consists of a nickel-based matrix reinforced with titanium diboride and chromium boride grains. The friction and wear behavior of the NKhTB20 coating in dry friction against plasma-sprayed NiCrSiB and NKhTB20 coatings is examined. It is revealed that the NKhTB20/NiCrSiB friction pair has higher wear resistance than NKhTB20/NKhTB20. The contact surfaces of the NKhTB20/NKhTB20 friction pair are damaged under oxidative and abrasive wear mechanisms. Oxidative wear is the dominant mechanism for the NKhTB20/NiCrSiB friction surface. Complex oxide films form on the NKhTB20/NiCrSiB sliding surface and prevent it from damage.

Powder Metallurgy V53, N11-12 2015 Structure...

Data

Jan 2016

Development of metal-matrix composites from industrial/agricultural waste materials and their derivatives

Article

Jan 2016

In this contribution, authors present a review on the state-ofthe-art in the utilization of industrial and agricultural waste materials for the development of metal�matrix composites (MMCs), providing, through the judicious analysis of an ample and varied references source � from the oldest to the newest ones � an insight into the challenges and opportunities for the exploitation to their full potential. In addition to its topicality, the novelty of this contribution lies in the presentation of key statistical, technical, and property-related information of a comprehensive variety of waste materials classed into two main groups, namely, fly ash reinforced MMCs and MMCs derived from other waste materials. Although fly ash has been exploited in a broad range of applications, the attention paid for its use in the development of MMCs seems to be insufficient. A purposely designed chart helped to pinpoint the more demanding and profitable applications of fly ash, and establish strategic opportunity areas. With the exception of the recent utilization of fly ash for the automotive industry, virtually no other waste material has been reused for a specific industrial application. In this context, by identifying five reasons for this observed delay, an essential goal of this review is to arouse the interest of academicians, scientists/technologists, and industrialists in the use of those materials for the fabrication of MMCs. In the case of agricultural materials, a twofold perspective may apply, because while on the one hand, certain chemical elements have to be removed for specific applications, on the other hand, recovery of certain elements might be more attractive. Based on the significant progress observed so far, in terms of scientific and technological research, a promising future can be anticipated. The proper use of industrial and agricultural waste materials entails knowledge generation as a prerequisite for incubation of pilot-plant and industrialization stages, culminating with all related benefits to society.

Development of metal-matrix composites from industrial/agricultural waste materials and their derivatives

Article

Full-text available

Oct 2015

M. I. Pech-Canul

In this contribution, authors present a review on the state-ofthe- art in the utilization of industrial and agricultural waste materials for the development of metal�matrix composites (MMCs), providing, through the judicious analysis of an ample and varied references source � from the oldest to the newest ones � an insight into the challenges and opportunities for the exploitation to their full potential. In addition to its topicality, the novelty of this contribution lies in the presentation of key statistical, technical, and property-related information of a comprehensive variety of waste materials classed into two main groups, namely, fly ash reinforced MMCs and MMCs derived from other waste materials. Although fly ash has been exploited in a broad range of applications, the attention paid for its use in the development of MMCs seems to be insufficient. A purposely designed chart helped to pinpoint the more demanding and profitable applications of fly ash, and establish strategic opportunity areas. With the exception of the recent utilization of fly ash for the automotive industry, virtually no other waste material has been reused for a specific industrial application. In this context, by identifying five reasons for this observed delay, an essential goal of this review is to arouse the interest of academicians, scientists/technologists, and industrialists in the use of those materials for the fabrication of MMCs. In the case of agricultural materials, a twofold perspective may apply, because while on the one hand, certain chemical elements have to be removed for specific applications, on the other hand, recovery of certain elements might be more attractive. Based on the significant progress observed so far, in terms of scientific and technological research, a promising future can be anticipated. The proper use of industrial and agricultural waste materials entails knowledge generation as a prerequisite for incubation of pilot-plant and industrialization stages, culminating with all related benefits to society.

Development of metal-matrix composites from industrial/agricultural waste materials and their derivatives- A review

Article

Jul 2015

In this contribution, authors present a review on the state-of-the-art in the utilization of industrial and agricultural waste materials for the development of metal–matrix composites (MMCs), providing, through the judicious analysis of an ample and varied references source – from the oldest to the newest ones – an insight into the challenges and opportunities for the exploitation to their full potential. In addition to its topicality, the novelty of this contribution lies in the presentation of key statistical, technical, and property-related information of a comprehensive variety of waste materials classed into two main groups, namely, fly ash reinforced MMCs and MMCs derived from other waste materials. Although fly ash has been exploited in a broad range of applications, the attention paid for its use in the development of MMCs seems to be insufficient. A purposely designed chart helped to pinpoint the more demanding and profitable applications of fly ash, and establish strategic opportunity areas. With the exception of the recent utilization of fly ash for the automotive industry, virtually no other waste material has been reused for a specific industrial application. In this context, by identifying five reasons for this observed delay, an essential goal of this review is to arouse the interest of academicians, scientists/technologists, and industrialists in the use of those materials for the fabrication of MMCs. In the case of agricultural materials, a twofold perspective may apply, because while on the one hand, certain chemical elements have to be removed for specific applications, on the other hand, recovery of certain elements might be more attractive. Based on the significant progress observed so far, in terms of scientific and technological research, a promising future can be anticipated. The proper use of industrial and agricultural waste materials entails knowledge generation as a prerequisite for incubation of pilot-plant and industrialization stages, culminating with all related benefits to society.

Recycled hardmetal-based powder composite coatings: Optimisation of composition, structure and properties

Article

Jan 2014

Hardfacing is among the most economical methods for surface treatment and service life and efficiency improvement of metal parts subjective to wear. At the same time use of low-cost recycling technologies in the production of powders is of current interest. Focus in this paper is on: a) the production of hardmetal/cermet powders as reinforcements for composite coatings; b) deposition technologies and optimisation of coating structure; c) the wear resistance of coatings at different abrasive wear conditions. The article describes the production and grindability of hardmetal (WC-Co) and cermet (Cr 3C2-Ni, TiC-NiMo) powders and their size and shape. Results address the optimisation of the composition and structure of HVOF-sprayed and PTA-welded composite powder coatings based on the commercial spray powders and produced hardmetal/cermet powders. The abrasive wear resistance of coatings at different wear conditions (rubber wheel, erosion and impact wear tests) is analysed.

Structure and properties of HVOF-sprayed and PTA-welded cermet hard phase reinforced Fe-matrix-based coatings

Article

May 2014

The aim of this study is to elaborate new composite coatings based on the hardmetal/cermet hard pahase – metallic-iron-based matrix for the heavy abrasive wear conditions. WC-based hardmetal and Cr-based cermet powders, produced by disintegrator milling, were used. Commercial Cr-Ni-steel and FeCrSiB alloy powders were used as matrix materials. Optimal content of hard phase (40 vol.%) was selected. For deposition of coatings, high-velocity oxyfuel (HVOF) spraying and plasma transferred arc (PTA) hardfacing were used. Three different wear testing methods namely abrasive rubber wheel wear (ARWW), abrasive erosive wear (AEW) and abrasive impact wear (AIW) were studied. Wear rates and relative wear resistance values were determined. As a result, the advantages of experimental composite coatings in comparison with commercial powder-based coatings were demonstrated.

Influence of hardness on the wear resistance of 17-4 PH stainless steel evaluated by the pin-on-disc testing

Article

Full-text available

Aug 2008
J MATER PROCESS TECH

Present work aimed at investigating the wear resistance of AISI 630 (UNS S17400) or 17-4 PH stainless steel hardened by precipitation hardening or aging at various hardness levels. The PHs steels are an interesting family of steels for applying in highly stressed parts for its corrosion resistance and relative high hardness, attaining up to 49 HRC by low-temperature aging heat treatment, low distortion and excellent weldability. The wear tests by sliding and/or abrasion were performed in a pin-on-disc tribometer whose pins had three different hardness levels (43, 37 and 33 HRC) obtained by varying the precipitation hardening treatment. The counterface discs were machined from the same steel composition and aged to the hardness of 43 HRC. The steels wear resistances were evaluated, using sliding velocity of 0.6m/s, normal load of 30N, total sliding distance of 2400m and controlled room temperature and humidity of 27°C and 60%, respectively. From the analysis of plotted graphs of cumulative lost volume versus sliding distance, it was observed the different wear rates as function of the heat treatment and hardness. Due to the pins different hardness, the wear resistance varied substantially. The wear mechanisms were also investigated through scanning electron microscopy observations of the worn surfaces of the pins. It can be asserted that the decrease in the pin hardness yields to lower pin wear resistance. The disc wear was more severe as the difference in hardness between pin and disc increased. It was presented a list of mean wear resistance, establishing the best heat treatment that minimize the wear in this material for sliding wear applications. For the investigated range of heat treatment and hardness, the 17-4 PH steel pins with hardness of 43 HRC showed the best wear resistance of 1941 and the pin with 33 HRC the worst wear resistance of 1581.

Plasma Transferred ARC (PTA) Hardfacing of Recycled Hardmetal Reinforced Nickel-matrix Surface Composites

Article

Full-text available

Apr 2012

The aim of this work was to apply coarse recycled hardmetal particles in combination with Ni-based matrix to produce wear resistant metal matrix composite (MMC) thick coatings using plasma transferred arc hardfacing (PTA) technology. Assignment of hardmetal waste as initial material can significantly decrease the production costs and improve the mechanical properties of coatings and, consequently, increase their wear resistance. The microstructure of MMC fabricated from a recycled powder was examined by optical and SEM/EDS microscopes, whereas quantitative analyses were performed by image analysis method. Micro-mechanical properties, including hardness and elastic modulus of features, were measured by nanoindentation. Furthermore, behaviour of materials subjected to abrasive and impact conditions was studied. Results show the recycled powder provides hardfacings of high quality which can be successfully used in the fabrication of wear resistant MMC coatings by PTA-technology.

Surface coatings for protection against wear

Book

May 2006

Brian G. Mellor

As wear is a surface or near surface phenomenon it has long been realised that the wear resistance of a component can be improved by providing a surface of different composition from the bulk material. Although this book concentrates on surface coatings, the distinction between surface coatings and the process of modifying the surface by changing its composition is not always clear, so some useful surface modification techniques are also considered. Surface coatings for protection against wear, consists of twelve chapters written by different authors, experts in their field. After a brief introductory chapter wear phenomena and the properties required from a coating are addressed. Chapter three covers coating characterisation and property evaluation relevant to wear resistance with an emphasis on mechanical testing of coatings. The next chapter provides an introduction to the various methods available to deposit wear resistant coatings. The following six chapters describe in detail wear resistant coatings produced by various deposition routes. Emphasis is placed on the microstructure property relationship in these coatings. Chapter eleven addresses coatings and hardfacings, produced from welding processes, specifically modern developments such as friction surfacing and pulsed electrode surfacing techniques. The final chapter is dedicated to future trends in both coating materials and coating processes. Surface coatings for protection against wear is essential for anyone involved in selecting coatings and processes and will be an invaluable reference resource for all engineers and students concerned with the latest developments in coatings technology.

Effect of carbide degradation in a Ni-based hardfacing under abrasive and combined impact/abrasive conditions

Article

Dec 2011
SURF COAT TECH

Within this work, the effect of carbide degradation in a WC/W2C reinforced Ni-based hardfacing was assessed under abrasive and combined impact/abrasive conditions. In view of the above, a WC/W2C reinforced Ni-based hardfacing was deposited by plasma transferred arc (PTA) welding using different welding currents. Microstructure was characterised by quantitative metallography to determine specific structural parameters: mean carbide diameter and carbide area fraction. Scanning electron microscopy (SEM, EDS) and X-ray diffraction (XRD) were also used to characterise carbide dissolution mechanism. Tribological behaviour was determined with a 3-body abrasion test according to ASTM G65 and with a cyclic impact/abrasion test (CIAT). Results showed significant carbide degradation with increasing welding current, resulting in a significant reduced primary carbide content and carbide diameter. Reduced carbide content indicated a significantly wear rate increase under pure 3-body abrasion conditions. Specific wear energy was determined under pure abrasive condition and showed significant dependence on the primary carbide content. However, wear rates under combined impact/abrasion were at constant level due to the reduction of the brittle primary carbide content.

Effect of temperature and load on three-body abrasion of cermets and steel

Article

Oct 2012
TRIBOL INT

Cermets surface transformation under erosive and abrasive wear

Article

Aug 2010
TRIBOL INT

The subsurface developed in ceramic–metal composites WC–Co, TiC–NiMo and Cr3C2–Ni during tribological testing (abrasion, sliding, erosion) under different conditions (impact angle, velocity, pressure, temperature) is the primary concern of the study. Mechanisms responsible for mechanically mixed layer (MML) development and wear resistance of materials are discussed in details. Instrumented indentation combined with consecutive polishing-testing procedure was used for mechanical characterisation. Microstructural features of the worn surface and subsurface region were studied with the help of optical microscope and scanning electron microscope equipped with energy dispersive spectroscopy analyser to evaluate difference between properties of the bulk and modified subsurface layers of materials.Formation of subsurface layer is found to be an essential feature of materials response to applied loading. Modified layer consists of highly deformed binder metal; cracked and decohesed large grains of carbides; embedded and/or fused debris of erosive/abrasive particles; and products of oxidation.

Advanced chromium carbide-based hardfacings

Article

May 2012
SURF COAT TECH

Microstructure and properties of hard and wear resistant MMC coatings deposited by laser cladding

Article

Mar 2009

Laser coating (laser cladding) is a useful method to produce metal matrix composite (MMC) coatings. The selection of the metallic matrix can be done on the base of the intended application and environment, whereas the additional wear resistance improvement is provided by mixing various carbides with the metallic matrix. In the present work, various types of MMC coatings were prepared by laser coating methods. The coatings consisted of vanadium, tungsten, titanium and chromium carbide hard phases mixed with metallic tool steel M2, Stellite 21, NiCrBSi-alloy and Inconel 625. Different levels of carbide contents were used. The abrasion resistance of the MMC coatings has been tested using a rubber-wheel abrasion apparatus. The wear surfaces were examined and the microstructures of MMC coatings were analysed in order to determine microstructures and carbide dissolution. The best abrasion results were achieved by the correct choice of carbide for each matrix material.

Wear Mechanisms at High Temperatures. Part 1: Wear Mechanisms of Different Fe-Based Alloys at Elevated Temperatures

Article

Jun 2009

To extend the lifetime of the sinter grate used to crush the sinter cake into smaller pieces for steel fabrication, a study was undertaken to investigate which wear processes are primarily responsible for limiting the lifetime of the sinter grate. Several wear processes could be identified. The sinter temperature which is up to 800°C causes temperature-induced material ageing and oxidation. The falling of the sinter cake onto the sinter grate causes high impacts, erosion and abrasive wear. There is enormous economic pressure, which makes the most cost-efficient solution the most attractive one, not the technically “best” coating material; thus, Fe–Cr–C hardfacing alloys are mostly used. In view of the above, four different alloys which are promising for this application were studied with regard to their wear resistance. Each wear mechanism was investigated in a special test tribometer. Fatigue wear caused by multiple impacts and abrasion was tested in the high-temperature continuous impact abrasion test. Materials behaviour in heavy single impacts was evaluated in the single impact test. Characterisation of microstructure and wear behaviour was performed by optical microscopy and scanning electron microscopy. The results obtained with the help of the different measurement techniques were linked and set into comparison to calculate the volumetric wear of the specimen. Aim of this work was to investigate the influence of the material parameters such as macrohardness, hard phase content, microstructure coarseness on the wear resistance in impact loading and abrasive applications at high temperatures. Results also indicate that the matrix ability to bind carbides at high temperature as well as the matrix hardness at high temperatures strongly influence the wear resistance in the different tests. Those material parameters get correlated to the wear rates in different material demands. The test results indicate that at higher temperatures material fatigue becomes a major wear-determining factor which makes the matrix hardness and the matrix ability to bind carbides at high temperatures very important. Especially, in abrasive wear, a certain content of hard phases is also necessary to keep the wear to a lower level. It could also be shown that in impact loading applications, a coarse microstructure is a disadvantage.

Metal-matrix composite coatings by PTA surfacing

Article

Dec 1998
COMPOS SCI TECHNOL

Metal-matrix composite (MMC) coatings are deposited onto ferrous and non-ferrous substrates by three conventional techniques, namely laser cladding, thermal spraying and plasma transferred-arc (PTA) surfacing. In this paper PTA surfacing technology is reviewed with reference to current surface modification applications. The main rationale behind this technology has been focussed towards enhancing the tribological properties of the substrate. Little effort has been directed to investigating the corrosion behaviour of these coatings. The methods used in surface modification are either metallic alloying or the deposition of a composite layer. The metallic-alloying process has gained wider acceptance than the latter technique. While ferrous and high-density materials are commonly treated, the surface treatment of low-density materials remains a research exercise.

Wear Behaviour of Recycled Hard Particle Reinforced NiCrBSi Hardfacings Deposited by Plasma Transferred Arc (PTA) Process

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