Investigation on Relationship Between Microstructural Characteristics and Mechanical Properties of Wire-Arc-Sprayed Zn-A
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Investigation on Relationship Between Microstructural Characteristics and Mechanical Properties of Wire-Arc-Sprayed Zn-Al Coating Amir Darabi1 • Fardad Azarmi1
Submitted: 8 June 2019 / in revised form: 25 August 2019 Ó ASM International 2019
Abstract Wire arc spraying is a cost-effective thermal spraying technology to deposit a protective coating layer on the surface of industrial components. Mechanical properties of wire arc spraying coatings are mainly influenced by their heterogeneous microstructure, resulting in complex and anisotropic mechanical properties. The objective of this investigation is to characterize the mechanical behavior of wire-arc-sprayed Zn-15Al alloy using an efficient micromechanical–computational scheme. Scanning electron microscopy images were imported to an object-oriented finite element scheme and distinguished into various phases, and then subsequently discretized into finite elements. To examine the validity of this technique, experimental studies, such as Knoop and Vickers microhardness, resonance frequency, and nanoindentation, were conducted on the freestanding coating samples. The elastic modulus of the coating was also calculated using wellknown analytical methods. Comparison of the results obtained in this study was used to investigate the relationship between the microstructural features and mechanical properties in coating materials. Image-based finite element analysis showed good agreement with the experimental measurements and proved the effect of splat boundaries on the reduction in mechanical strength between coating layers and, consequently, lower elastic
This article is an invited paper selected from presentations at the 2019 International Thermal Spray Conference, held May 26-29, 2019 in Yokohama, Japan, and has been expanded from the original presentation. & Fardad Azarmi [email protected] 1
Department of Mechanical Engineering, North Dakota State University, Fargo, ND 58108, USA
modulus of the wire-arc-sprayed Zn-15Al coating in the longitudinal direction compared to the transversal one. Keywords corrosion protection finite element modeling mechanical properties microstructure wire arc spraying Zn-Al
Introduction Thermal spraying is an advantageous method for depositing protective layers on the surface of parts, components, and structures. Coatings deposited by thermal spraying techniques have found many applications in aerospace, automotive, biomedical, electrical, and turbine industries (Ref 1). Wire arc spraying is a member of thermal spraying family that has found extensive commercial use thanks to its low cost, ease of use, and relatively high deposition rate compared to other thermal spraying techniques (Ref 2). Metals with good corrosion resistance, such as zinc and aluminum (Ref 3-5), could be deposited via wire arc deposition or flame spray techniques to improve the anticorrosion properties of industrial components; this process is known as ‘‘Metallization’’ (Ref 6, 7). Recently, it has become popular in the pipeline industr
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