Surface modification of tungsten carbide cobalt by electrical discharge coating with quarry dust suspension
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ORIGINAL ARTICLE
Surface modification of tungsten carbide cobalt by electrical discharge coating with quarry dust suspension Ching Yee Yap 1 & Pay Jun Liew 1
&
Jiwang Yan 2
Received: 12 June 2020 / Accepted: 15 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This study explores the feasibility of reusing waste quarry dust as a coating material for surface modification of tungsten carbide cobalt (WC-Co) using electrical discharge coating (EDC). The main objective is to investigate the effect of quarry dust suspension with different concentrations (0–40 g/l) on the characteristics of coated surface such as coating layer thickness, coating element composition and chemical compound, surface morphology, surface roughness and Vickers micro-hardness. Before the EDC process, characterisation of the raw quarry dust was conducted through scanning electron microscopy, X-ray fluorescence and particle size analyser. The results showed that the coating layer thickness was strongly affected by the quarry dust concentration. The formation of hard carbides (SiC, Mg2C3, Fe2C and CaC2) and oxide phases (SiO2, Al2O3, Fe2O3, CaO, CoO and ZnO) in the coated layer due to material migration was confirmed through X-ray diffraction analysis. Vickers micro-hardness of the coated surface was improved significantly with the addition of quarry dust. The best surface finish without micropores and microcracks was obtained using a quarry dust concentration of 10 g/l. These results demonstrated the capability of recycling quarry dust as an environmentally friendly coating material for surface modification. Keywords Waste quarry dust . Electrical discharge coating (EDC) . Tungsten carbide cobalt (WC-Co) . Surface modification . Material migration
1 Introduction Quarry dust is a by-product created during the crushing process of stones to obtain concrete aggregates. According to Sridharan et al. [1], in each crusher unit, approximately 20– 25% of total production leaves quarry dust as waste material in the environment. This condition has become one of the challenging issues that have led to adverse effects such as dust pollution and environmental deterioration. To solve the disposal problem of these industrial wastes, researchers are striving to convert them into utilisable raw materials for practical application. For example, Ramesh et al. [2] used modified stir casting to reinforce aluminium * Pay Jun Liew [email protected] 1
Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Melaka, Durian Tunggal, Malaysia
2
Department of Mechanical Engineering, Faculty of Science and Technology, Keio University, Hiyoshi 3-14-1, Yokohama, Kohoku-ku 223–8522, Japan
alloy (A356) with quarry dust particulates. The researchers found that tensile strength, hardness and wear resistance were significantly improved with the alloying of quarry dust particulates in the aluminium (Al). Xavier and Suresh [3] also discovered that the wear resistance of Al metal matrix composites increase
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