Effect of Feedstock Size and its Distribution on the Properties of Detonation Sprayed Coatings |
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Authors: | P Suresh Babu D S Rao G V N Rao G Sundararajan |
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Affiliation: | (1) International Advanced Research Center for Powder Metallurgy and New Materials (ARCI), Balapur (P.O), Hyderabad, 500 005, India |
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Abstract: | The detonation spraying is one of the most promising thermal spray variants for depositing wear and corrosion resistant coatings.
The ceramic (Al2O3), metallic (Ni-20 wt%Cr) , and cermets (WC-12 wt%Co) powders that are commercially available were separated into coarser
and finer size ranges with relatively narrow size distribution by employing centrifugal air classifier. The coatings were
deposited using detonation spray technique. The effect of particle size and its distribution on the coating properties were
examined. The surface roughness and porosity increased with increasing powder particle size for all the coatings consistently.
The feedstock size was also found to influence the phase composition of Al2O3 and WC-Co coatings; however does not influence the phase composition of Ni-Cr coatings. The associated phase change and %porosity
of the coatings imparted considerable variation in the coating hardness, fracture toughness, and wear properties. The fine
and narrow size range WC-Co coating exhibited superior wear resistance. The coarse and narrow size distribution Al2O3 coating exhibited better performance under abrasion and sliding wear modes however under erosion wear mode the as-received
Al2O3 coating exhibited better performance. In the case of metallic (Ni-Cr) coatings, the coatings deposited using coarser powder
exhibited marginally lower-wear rate under abrasion and sliding wear modes. However, under erosion wear mode, the coating
deposited using finer particle size exhibited considerably lower-wear rate. |
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Keywords: | Al2O3 fracture toughness Ni-Cr thermal spray tribological properties WC-Co |
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