Comparative Wear Behavior of Semicrystalline HVOF and Plasma Sprayed Phosphorous-Rich Pig Iron Coatings
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Comparative Wear Behavior of Semicrystalline HVOF and Plasma Sprayed Phosphorous-Rich Pig Iron Coatings T. D. Naidu1 • Prabhat K. Rai1 • K. Sarkar2 • P. Bijalwan2 • A. Pathak2 M. Dutta2 • A. Banerjee2 • K. Mondal1
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Submitted: 24 February 2020 / in revised form: 12 September 2020 / Accepted: 14 September 2020 ASM International 2020
Abstract The present work discusses the comparative wear behavior of composite (amorphous/nanocrystalline) blast furnace pig iron coatings deposited on a mild steel substrate using high velocity oxygen fuel and air plasma spray techniques. The study has been carried out using a ball-on-disk tribometer with the coated specimen and tungsten carbide ball as disk and counter body, respectively. A composite structure, consisting of both amorphous and nanocrystalline phases, has been confirmed by x-ray diffraction and transmission electron microscopy. It has indicatively been shown that the wear resistance of the mild steel substrate could be improved using composite coatings due to the higher micro-hardness of the coatings. Indirect tribo-oxidation involving oxidized debris has been found to be the dominant wear mechanism. Keywords amorphous/nanocrystalline coating APS HVOF pig iron wear
Introduction Most of the engineering failures initiate at the surface of the components, which are subjected to wear and corrosion (Ref 1). Therefore, the quest for developing materials with superior wear and corrosion resistance still continues. In recent years, bulk metallic glasses (BMGs) have drawn & K. Mondal [email protected] 1
Department of Materials Science and Engineering, Indian Institute of Technology, Kanpur 208016, India
2
Research and Development Division, Tata Steel, Jamshedpur 831007, India
great attention due to their high resistance to wear and corrosion along with excellent mechanical properties, like high strength and hardness (Ref 2). BMGs are non-crystalline solids and one way to obtain these is by quenching the liquid metal at very high cooling rates (Ref 2). The absence of lattice defects, like dislocations, provides excellent resilience, corrosion and wear resistance to the amorphous alloys as compared with crystalline metals and alloys (Ref 1-6). Hence, they find applications in the production of golf club heads, various shapes in optical mirrors, shot peening balls, electromagnetic shielding plates, high corrosion-resistant coated plates and various sports equipment and cases for electronic equipment, etc. (Ref 5, 6). But their poor mechanical stability (Ref 5) and intrinsic brittleness (Ref 7) can lead to catastrophic failure. Moreover, the difficulty in synthesizing them in bulk form limits their structural usage. In order to overcome these drawbacks, amorphous/nanocrystalline coatings have been developed to utilize the attractive properties of amorphous materials as well as materials with mixed amorphous/nanocrystalline structure for the improvement of wear, corrosion and fatigue resistance (Ref 2, 5, 8). Of all classes of amorphous alloys, Fe-bas
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