Oxidation performance of Fe-Al/WC composite coatings produced by high velocity arc spraying

Fe-Al intermetallics with remarkable high-temperature intensity and excellent erosion, high-temperature oxidation and sulfuration resistance are potential low cost high-temperature structural materials. But the room tem perature brittleness induces shape difficult and limits its industrial application. The Fe-Al intermetallic coatings were prepared by high velocity arc spraying technology with cored wire on 20G steel, which will not only obviate the problems faced in fabrication of these alloys into useful shapes, but also allow the effective use of their outstanding high-temperature performance. The Fe-Al/WC intermetallic composite coatings were prepared by high velocity arc spraying technology on 20G steel and the oxidation performance of Fe-Al/WC composite coatings was studied by means of thermogrativmetic analyzer at 450, 650 and 800 ℃. The results demonstrate that the kinetics curve of oxidation at three temperatures approximately follows the logarithmic law. The composition of the oxidized coating is mainly composed of Al2 O3, Fe2 O3, Fe3 O4 and FeO. These phases distribute unevenly. The protective Al2 O3 film firstly forms and preserves the coatings from further oxidation.     

Influence of oxides on high velocity arc sprayed Fe-Al／Cr3C2 composite coatings

Fe-Al/Cr3C2 coatings were sprayed on low steel by high velocity arc spraying(HVAS) technology. The influences of oxides on erosion, corrosion and wear behavior for high velocity arc sprayed Fe-Al/Cr3C2 coatings were studied. The results show that HVAS-sprayed Fe-Al/Cr3C2 coatings have good erosion, heat corrosion and wear resistance. The erosion resistance improves with the increase of the temperature. On one hand, the ferrous oxides are incompact, so they peel off the surface of the coatings easily during the high temperature erosion. On the other hand, compact Al2O3 films on the surface can protect the coatings.     

Fatigue properties of 48MnV steel with twin arc spraying 3Cr13 coatings

The fatigue behaviors of 48MnV steel, both uncoated and coated with different thicknesses of 3Cr13 deposits using twin arc spraying, were investigated. The fatigue properties of the 48MnV steel, determined under axial loading conditions, can be substantially decreased by coating 3Cr13 films, deposited by twin arc spraying. And the fatigue behavior of the thinner coatings is better than that of the thicker ones, of which the fatigue limits decrease by 9%–14%. The decrease in fatigue life attributes to the less mechanical properties of the coatings in comparison with those of the substrate, their relative bad bonding strength and trapped oxide or Al₂O₃ particles retain in the matrix after blasting responsible for the initiation of fatigue cracks. Foundation item: Project (50235030) supported by the National Natural Science Foundation of China     

Sand-wear resistance of brush electroplated nanocomposite coating in oil and its application to remanufacturing

Sand-wear resistance of nano scale alumina particle reinforced nickel matrix composite coating (n-Al₂O₃/Ni) prepared by brush electroplating technique was investigated via wear tests in sand-contaminated oil lubricant, comparing with that of AISI1045 steel and brush electroplated Ni coating. Effects of testing load, sand content and sand size on worn volume of the three materials, and also coating surface roughness on worn volume of the brush electroplated coatings were accessed. Results show that the worn volume of all the three materials increases with increasing of testing load, sand content and sand size. In the same conditions, n-Al₂O₃/Ni composite coating has the smallest worn volume while AISI1045 steel has the largest because of the n-Al₂O₃ particle effects. As to n-Al₂O₃/Ni and Ni coatings, the surface-polished coatings have obviously lower worn volume than the as-plated coatings. The brush electroplated n-Al₂O₃/Ni composite coating was employed to remanufacture the sand-worn bearing seats of a heavy vehicle and good results were gained. Foundation item: Project (50235030) supported by the National Natural Science Foundation of China; Project (51489020104ZD0401) supported by the National Key Laboratory for Remanufacturing; Project(51418060105JB3058) supported by National Defence Foundation     

Bonding mechanism of X10CrNi18-8 with Ni/Al_2O_3 composite ceramic by pressureless infiltration

An alloy steel/alumina composite was successfully fabricated by pressureless infiltration of X10CrNi18-8 steel melt on 30%(mass fraction) Ni-containing alumina based composite ceramic(Ni/Al2O3) at 1 600 ℃.The infiltration quality and interfacial bonding behavior were investigated by SEM,EDS,XRD and tensile tests.The results show that there is an obvious interfacial reaction layer between the alloying steel and the Ni/Al2O3 composite ceramic.The interfacial reactive products are(FexAly)3O4 intermetallic phas...     

Abrasive wear behaviors of high velocity arc sprayed iron aluminum composite coatings

The High Velocity Arc Spraying （HVAS） technology was used to prepare Fe-Al composite coatings by the adding of different elements into cored wires to obtain different Fe-Al coatings. The added compounds do great effect on the properties of the composite coatings. The microstructures and abrasive wear performances of the coatings were assessed by transmission electron microscopy （TEM）, scanning electron microscopy （SEM）, and THT07-135 high temperature wear equipment. It was found that the adding of Cr3C2 can greatly increase the room temperature wear behavior, and Fe-Al/WC coatings have adapting periods at the beginning of wear experiment. With the rise of temperature, the wear resistance of Fe-AI/Cr3C2 coatings becomes bad from room temperature to 250℃, and then stable from 250℃ to 550℃; the wear resistance of Fe-Al/WC becomes well with the rise of temperature. The adding of Cr and Ni can also improve wear performances of Fe-Al composite coatings.     

Influence of oxides on high velocity arc sprayed Fe-Al/Cr_3C_2 composite coatings

1INTRODUCTION Arcspraying(AS)isatechniquethatthemet alisheatedtodropletsbyanelectricarcandthensprayedontosubstratesbythecompressedair. Highvelocityarcspraying(HVAS)technologyisdevelopedonthebasisofAS.Aspecialtubede signedaccordingtotheprincipleofaerodynamicsis mountedattheexitofcompressedair.Theveloci tyanddistributionofmelteddropletsbecomehigh erandmoreuniform,respectively.Asaresult,acoatingwithlowporosity(2%)andhighdensity andbondstrengthcanbeobtained[15].Fe Alin termetalliccompound…     

New pattern Zn-Al-Mg-RE coating technics for steel structure sustainable design

Based on the advanced integrated technology of materials preparation and formation, a new pattern Zn-Al-Mg-RE anti-corrosion coating for steel structure sustainable design was manufactured by cored wires and high velocity arc spraying (HVAS) technologies. The developments of thermally sprayed coatings for steel structure protection were described. Based on Al, Zn, Zn-Al and Zn-Al-Mg coatings, the anti-corrosion properties of new-pattern Zn-Al-Mg-RE coating were evaluated through electrochemical methods including electrochemical polarization and electrochemical impedance spectroscopy (EIS) coupled with SEM and XRD. The models of Zn-Al-Mg-RE coating undergoing corrosion with the initial pinhole defect and the latter with accelerated products were also discussed. The results show that Zn-Al-Mg-RE coating exhibites excellent corrosion resistance for long-term immersion, which is helpful for the sustainable design of steel structure in aggressive corrosion conditions. And the corrosion products seem to possess certain self-sealing function. Foundation item: Project (50235030) supported by the National Natural Science Foundation of China     

Electronic structure and FIM imaging mechanism of Fe-Al intermetallic compounds

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Cyclic oxidation behavior of Fe-9Cr-1Mo steel in water vapor atmosphere

The cyclic oxidation behavior of Fe-9Cr-1Mo steel (9Cr-1Mo) in 10%H₂O+90%Ar (volume fraction) atmosphere at 600, 650 and 700 for °C various time was studied. The oxidation mechanism of 9Cr-1Mo steel in 10%H₂O+90%Ar atmosphere was discussed. The thermal stress was evaluated in two oxide layers to illustrate the spallation of the oxide layer. The experimental results indicate that there exists a duplex oxide scale with an outer layer of Fe₂O₃ and an inner layer of mixed (Fe, Cr)₃O₄ formed on 9Cr-1Mo steel during cyclic oxidation. Some cracks generated in both inner and outer oxide layers. Parts of oxide scales spalled from substrate during the cyclic oxidation. A higher tensile stress in the oxide layer is formed at the early oxidation stage than at the later oxidation stage during heating. This tensile stress results in the formation of cracks in the oxide layer. Foundation item: Project(2006–8) supported by the Huadian International Corporation Limited     

Fatigue life prediction of crankshaft repaired by twin arc spraying

This paper used Baumel Jr. and Seeger’s approach estimating fatigue parameters of 48MnV with 3Cr13 coatings. The fatigue life of the crankshaft of a six-cylinder engine, repaired by twin arc spraying 3cr13 deposits, is respectively calculated using different damage model such as S-N method, normal strain approaches, SWT-Bannantine approaches, shear strain approaches, and fatemi-Socie method based on dynamical simulation and FE analysis of crankshaft. The results indicate that the traditional calculation is conservative and that the life of crankshaft repaired by arc spraying is sufficient. Foundation item: Project (50235030) supported by National Natural Science Foundation of China     

Thermodynamics calculation on the oxidation and sulfur removal abilities of slag in EAF dust pellet reduction process

ＥＡＦｄｕｓｔｈａｓｂｅｅｎｃｌａｓｓｉｆｉｅｄａｓｈａｚａｒｄｏｕｓｗａｓｔｅ ,ａｎｄｉｔｉｓｈａｒｍｆｕｌｉｎｔｈｅｃｏｎｖｅｎｔｉｏｎａｌｌａｎｄ ｆａｌｌｄｕｅｔｏｃｏｎｔａｉｎｉｎｇｈｅａｖｙｍｅｔａｌｓ[1] .Ｍｏｓｔｒｅｃｙ ｃｌｉｎｇｍｅｔｈｏｄｓ[2 8] ｄｅｖｅｌｏｐｅｄｆｏｒｔｈｅｄｕｓｔｓａｒｅｏｎｌｙｆｏｒｔｈｅｒｅｃｏｖｅｒｙｏｆｌｅａｄ ,ｚｉｎｃａｎｄｃａｄｍｉｕｍ .ＴｈｅＥＡＦｄｕｓｔｆｒｏｍｓｔａｉｎｌｅｓｓｓｔｅｅｌｍａｋｉｎｇｍａｉｎｌｙｃｏｎ ｔａｉｎｓｎｉｃｋｅ…     

Influence of surface finish and annealing treatment on oxidation behavior of Ti-48Al-8Cr-2Ag alloy

The effect of surface finish and annealing treatment on the oxidation behavior of Ti-48Al-8Cr-2Ag (molar fraction, %) alloy was investigated at 900 and 1 000 °C, respectively in air. Thermal gravimetric analysis (TGA) was conducted for the characterization of oxidation kinetics. The microstructures of oxide scales were studied by scanning electron microscopy (SEM) and transmission election microscopy (TEM) techniques. Unfavorable effect of the annealing treatment on the oxidation behavior of the coating was also investigated. The results indicate that the oxidation behavior of the alloy is influenced by surface finish and annealing treatment. The oxidation rate of ground sample is lower than that of the polished alloy at 1 000 °C in air. The former forms a scale of merely Al₂O₃, and the latter forms a scale of the mixture of Al₂O₃ and TiO₂. Annealing can improve the formation of TiO₂. Foundation item: Project(2007430028) supported by the Science and Technique Foundation of Henan Educational Committee, China     

Preparation of Fe-Al Intermetallie /TiC-Al2O3 Ceramie Composites from llmenite by SHS

Fe-Al intermetallic/TiC-Al2O3 ceramic composites were successfully prepared by selfpropagating high-temperature synthesis （SHS） from natural ilmenite, aluminium and carbon as the raw materials. The effects of carbon sources, preheating time and heat treatment temperature on synthesis process and products were investigated in detail, and the reaction process of the FeTiO3-Al-C system was also discussed. It is shown that the temperature and velocity of the combustion wave are higher when graphite is used as the carbon source, which can reflect the effect of the carbon source structure on the combustion synthesis; Prolonging the preheating time or heat treatment temperature is beneficial to the formation of the ordered intermetallics; The temperature and velocity of the combustion wave are improved, but the disordered alloys are difficult to eliminate with the preheating time prolonged. The compound powders mainly containing ordered Fe3Al intermetallic can be prepared through heat treatment at 750 ℃.     

Microstructures and mechanism of Al<Subscript>2</Subscript>O<Subscript>3</Subscript>/Al composites fabricated by the reaction between SiO<Subscript>2</Subscript> and molten aluminum

Al₂ O₃/Al composite was fabricated by the reaction between SiO₂ and molten aluminum. The microstructures of the composite obtained under different reaction conditions were analyzed. The formation mechanism of the composite microstructure was discussed. Results show that the reaction kinetics is influenced remarkably by the reaction temperature, reaction time and the quantity of SiO₂. The morphologies of Al₂O₃ have different features, depending on the reaction temperature. The composite has equaxed Al₂O₃ grains when materials reacted below 1200°C, and the composite is composed of a large number of fine Al₂O₃ grains and aluninum. The composite has a frame-shaped Al₂O₃ microstructure at the reaction temperature of above 1250°C. CHENG Xiao-min: Born in 1964 Funded by the National Natural Science Foundation of China (No. 91522)     

Laser cladding Al-Si/Al2O3-TiO2 composite coatings on AZ31B magnesium alloy

To improve the wear resistance and corrosion resistance of magnesium alloys, a 5 kW continuous wave CO₂ laser was used to investigate the laser surface cladding on AZ31B magnesium alloys with Al-Si/Al₂O₃ -TiO₂ composite powders. A detailed microstructure, chemical composition, and phase analysis of the composite coatings were studied by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The laser cladding shows good metallurgical bonding with the substrate. The composite coatings are composed of Mg₁₇Al₁₂, Al₃Mg₂, Mg₂Si, Al₂O₃, and TiO₂ phases. Compared to the average microhardness (50HV_0.05) of the AZ31B substrate, that of the composite coatings (230HV_0.05) is improved significantly. The wear resistances of the surface layers were evaluated in detail. The results demonstrate that the wear resistances of the laser surface-modified samples are considerably improved compared to the substrate. It also show that the composite coatings exhibit better corrosion resistance than that of the substrate in 3.5wt% NaCl solution.     

The influence of mo additive on the microstructure and property of Ti/Al<Subscript>2</Subscript>O<Subscript>3</Subscript> composite

The influence of Mo on the microstructure, bending strength and HV of Ti/Al₂O₃ composite was studied, and the influence mechanism was analyzed. The results indicate that after the addition of Mo, the composite organization is finer and phases distribution is better-proportioned which make the microstructure denser, the bending strength and HV of composite are also increased to a degree. But the bending strength increases first then decreases with the increasing of Mo content, so the appropriate Mo content for the Ti/Al₂O₃ composite is to be further confirmed. WANG Zhi: Born in 1962 Funded by Natural Science Foundation of China (No. 50232020) and Natural Science Foundation of Shandong Province (No. 2002F21)     

热喷涂FeCrAl/Al复合涂层抗高温硫化的研究

为了提高材料的抗热腐蚀性能,采用电弧喷涂方法在钢铁基体表面施加FeCrAl/Al复合涂层,通过沉积Na2SO4的900℃热腐蚀试验以及二硫化碳生产装置中的现场挂片试验,研究了FeCrAl/Al复合涂层的高温硫化表现。实验结果表明:FeCrAl/Al复合涂层提高了钢铁材料的抗高温硫化腐蚀能力,在高温硫化初期,外表面的Al涂层首先发生氧化,形成连续的Al2O3层,显著地减缓了硫原子向复合涂层内部的扩散速度。随着复合涂层中Cr、Al等有效抗硫化合金元素的相互扩散,形成FeCr金属间化合物层,进一步阻碍硫原子扩散,对钢铁基体材料提供有效的高温硫化防护作用。     

Effect of cobalt loading on reducibility, dispersion and crystallite size of Co／Al2O3 Fischer-Tropsch catalyst

Co/Al2O3 Fischer-Tropsch synthesis catalysts with different cobalt loadings were prepared using incipient wetness impregnation method. The effects of cobalt loading on the properties of catalysts were studied by means of X-ray diffraction (XRD), temperature programmed reduction (TPR), hydrogen temperature programmed desorption (H2-TPD) and O2 titration. Co-support compound formation can be detected in catalyst system by XRD.For the Co/Al2O3 catalysts with low cobalt loading, CoAl2O3 phase appears visibly. Two different reduction regions can be presented for Co/Al2O3 catalysts, which belong to Co3 O4 crystallites (reduction at 320 ““C) and cobalt oxidealumina interaction species (reduction at above 400℃). Increasing Co loading results in the increase of Co3 O4 crystallite size. The reduced Co/Al2O3 catalysts have two adsorption sites, and cobalt loading greatly influences the adsorption behavior. With the increase of cobalt loading, the amount of low temperature adsorption is increased, the amount of high temperature adsorption is decreased, and the percentage reduction and cobalt crystallite size are increased.     

Mn_2O_3/PANI的制备及其防腐性能研究

采用溶剂热法制备Mn_2O_3微球,与化学氧化法制备的聚苯胺按不同比例混合,制得Mn_2O_3/PANI,将其涂覆于Q235碳钢表面制备复合涂层.采用扫描电镜(SEM)、原子力显微镜(AFM)、X射线衍射(XRD)和红外光谱(FTIR)表征Mn_2O_3/PANI的表面形貌和结构,利用动电位极化和电化学阻抗谱研究复合涂层的耐蚀性能.结果表明,当Mn_2O_3在复合材料中的质量分数为10%时,防腐性能最优.在3.5%NaCl溶液中浸泡7天后,相较于Q235裸钢,其自腐蚀电位正移约380 mV,自腐蚀电流密度降低约3个数量级;浸泡37天后,其仍有良好的稳定性和耐蚀性.