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C/min up to 500
C
Velocity
Temperature
Fig. 3 In-ight particles velocity and temperature. Each error bar shows
the maximum value and minimum value obtained by all data.
1672 Y. Ishikawa, J. Kawakita and S. Kuroda
particles in-ight temperature. Lidong et al. investigated the
inuence of the spray particles in-ight velocity and the
spray particles in-ight temperature exerted on hardness of
WC-CoCr coating on mild steel St 37 made by HVOF. The
coatings hardness increased with increasing the spray
particles in-ight velocity and the spray particles in-ight
temperature.
14)
From these results, we consider that the
coating hardness was increased with increasing of the work
hardening or the residual stress that were increased by the
increase of the spray particles in-ight velocity.
The coating made by the GS-HVOF process was heat-
treated at 500
C showed the
greatest increase, i.e. the hardness was increased from Hv750
to HV1100. The amount of voids in the coatings was
calculated by the image processing of SEM image. The
increase of the hardness was attributed to the decrease of
voids in the coatings. Since the coating by GS-HVOF in the
present study has essentially no voids and pores in the as
spray condition. Therefore, the coating hardness was not
increased by the heat-treatment.
We observed the cross section of the coatings by using
SEM (Fig. 5). Boundaries among the particles were observed
in the coating prepared with the oxidizing ame. Pores and
voids are also visible on the cross section. Lamellar structure
was slightly revealed in the cross section of the coating
prepared by the reducing ame. The spray particles boundary
(lamellar structure) decrease gradually as it goes from the
oxidizing ame to the reducing ame. By using the gas
shroud equipment, boundaries are hardly observed and the
lamellar structure cannot be identied. This result indicates
the improvement in density of coatings by the gas shroud
attachment.
The crystal structures of the coating were characterized
from the surface by XRD (Fig. 6). We conrmed the
existence of Cr
3
C
2
and Cr
2
O
3
peak. The ratio of Cr
2
O
3
Cr
3
C
2
was calculated by using the intensity of the main peak
of each material (Fig. 7). The heat-treated coating showed
the highest oxidation degree in all the specimens. During heat
treatment (at high enough temperature) oxygen combines
with Cr in the coating to form Cr
2
O
3
.
16)
The XRD diraction
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
600 650 700 750 800 850 900
In-flight velocity of particles, V/m?s
-1
V
i
c
k
e
r
s
h
a
r
d
n
e
s
s
,
H
v
0
.
3
Fig. 4 The relationship between the coating hardness and In-ight
particles velocity. The hardness values are the averages of ten measure-
ments on each sample. Each error bar shows the maximum value and
minimum value obtained by all data.
5m
Void
WC
CrC
Ni
Boundary
5m
Reducing
Flame
Oxidizing
Flame
5m
5m
Gas
Shroud
Heat
Treatment
CrC
WC
CrC
Boundary
WC
Ni
Ni
CrC
WC
Ni
Fig. 5 Cross section SEM image of coatings. White: WC, Light gray: Ni, Black: Cr
3
C
2
.
Eect of Spray Condition and Heat Treatment on the Structure and Adhesive Wear Properties of WC Cermet Coatings 1673
spectrum of the heat-treated coating shows peaks indexed to
NiWO
4
. However, after polishing 50 mm by an abrasive
paper, the oxidation degree was decreased and XRD peaks of
inside of coating was similar to that of gas-shroud coatings.
The coating by the reducing ame showed the highest
oxidation degree among the untreated specimens.
This result was in agreement with Kreyes research, which
showed the eect of F/O ratio on the oxide content of the
coatings.
17)
The formation of oxide during the thermal spray
process can be categorized into three regions.
18)
Region 1 is
in the jet core, region 2 is in the atmosphere from the outside
of jet ame to the substrate and region 3 is on the substrate.
The spray particles in-ight temperature with the reducing
ame was little higher than that by the other ames. The
oxygen content of the coatings depends not only by the heat
of jet ame, but also by the substrate temperature. Since the
reducing ame burns further at the outside of the nozzle exit,
the substrate temperature should be higher than other
combustion ames. Therefore, the coating by the reducing
ame showed the highest oxidation degree among the
untreated specimens.
Figures 8 and 9 show the specic wear rates of the coatings
and the iron pin. Each error bar shows the maximum value
and minimum value of the specic wear rate obtained by 3
runs. The specic wear rate of the coating prepared by the
oxidizing ame was greater than the other coatings. The
specic wear rate of the coating prepared by the reducing
ame and GS-HVOF ame was in the order of 10
9
mm
2
/N
and was close to that of chrome plating. The specic wear
rate of the heat-treated coating is shown as zero, because the
wear amount of the heat-treated coating could not be detected
after the wear testing. Even though hardness is not dierent
between the heat-treated GS coating and the untreated GS
coating, the specic wear rate of the heat-treated GS coating
is much lower than that of the untreated GS coating. From the
result of Fig. 7, we consider that the adhesive wear property
was inuenced by the existence of oxides.
The specic wear rate of the iron pin was in the order of
10
8
mm
2
/N except for the combination of the iron pin and
the coating prepared with the oxidizing ame. Although the
wear amount of the heat-treated coating could not be detected
after the wear testing, the specic wear rate of the pin showed
a value in the order of 10
8
mm
2
/N, which is little higher
than that of the iron pin against the coatings prepared by the
GS-HVOF.
With the comparison of these wear behaviour, it is obvious
that the specic wear rate of the combination of the oxidizing
ame coating was the highest among the tested combinations.
However, even in this case the specic wear rate of the pin
was just above 10
7
mm
2
/N. From such low wear rates of
both the pin and the coatings, it is likely that the wear of all
the combinations was in the mild wear mode after 3000 m
WC, W
2
C, WO
3
, Cr
3
C
2
, Cr
2
O
3
, NiO, NiWO
4
30 40 50 60 70 80 90
30 40 50 60 70 80 90
-Heat treatment
-Heat treatment
(50mm inside)
30 40 50 60 70 80 90
-Oxidizing flame
-Reducing flame
-Gas shroud
2
Fig. 6 XRD patterns of coatings.
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Oxydizing flame Reducing flame GS Heat treatment
T
h
e
r
e
l
a
t
i
v
e
i
n
t
e
n
s
i
t
y
o
f
C
r
2
O
3
/
C
r
3
C
2
Fig. 7 Oxidation degree during spraying in terms of the XRD intensity
ratio of Cr
2
O
3
/Cr
3
C
2
.
0
0.5
1
1.5
2
2.5
Oxidizing
flame
Reducing
flame
Gas shroud Chrome
plating
Heat treated
S
p
e
c
i
f
i
c
w
e
a
r
r
a
t
e
,
W
/
1
0
-
8
m
m
2
N
-
1
Fig. 8 Specic wear rate of coatings.
0
5
10
15
20
25
Oxidizing
flame
Reducing flame Gas shroud Chrome plating Heat treated
S
p
e
c
i
f
i
c
w
e
a
r
r
a
t
e
,
W
/
1
0
-
8
m
m
2
N
-
1
Fig. 9 Specic wear rate of iron pin.
1674 Y. Ishikawa, J. Kawakita and S. Kuroda
sliding.
To examine the severe to mild wear transition, we recorded
the displacement of the pin head as shown in Fig. 2.
Figure 10 shows the obtained typical displacement curves.
The inclination of specic wear rate slightly changes by each
measurement. Since the wear amount of coatings is very low,
the displacement curve of d may be regarded as the wear
behaviour of iron pin.
In our experiments, only the coating made by the oxidizing
ame showed the severe-mild wear transition at 50 m,
whereas the other coatings did not show the severe-mild
wear transition. Since the coating made by the oxidizing
ame has the highest porosity and the particles boundary is
more obvious larger wear debris might be generated easily at
early wear stage, because of detachment of loosely bonded
sprayed particles. Since small oxide wear debris is generated
by crushing such larger wear debris, the wear behaviour of a
coatings changes from severe wear to mild wear. Therefore,
we consider that only the coating made by the oxidizing
ame showed the severe-mild wear transition.
Furthermore, we observed the wear debris of the latter
coatings without severe-mild wear transition during wear
testing. Dark-colored and small (15 mm) wear debris was
generated on the surface at an early wear stage. Wear tracks
and the iron oxide existed on the surface of the coating after
wear testing. As latter coatings showed the low specic wear
rate (10
8
mm
2
/N), these results indicated that the latter
coatings realized the mild wear condition at a very early stage
of testing.
In previous work,
19)
we found that the abrasive wear
resistance of the coatings depended on the hardness of the
coatings. However, in the adhesive wear mode such as the
pin-on-disk type wear test in this study, the wear rate does not
simply depend on the hardness of coatings but also on the
chemical composition of the coating surface. XRD analysis
of the heat-treated coating from surface indicated the peaks
of NiWO
4
, WO
3
. It seems that the adhesive wear property
was inuenced by the existence of these oxides.
Kato investigated the inuences of oxide particles supplied
to the rubbing surface during sliding on the severemild
wear transition by using a pin-on-disc wear tester.
20)
As a
result, oxide particles were found to play an important role in
reducing the amount of wear. The sever-mild wear transition
distance was decreased by decreasing the size of the supplied
oxide particles.
He surmised that this eect is caused by the formation of
the oxide layers on the rubbing surfaces.
In addition, Picas et al. reported that the specic wear rate
of thermal sprayed nanocrystalline CrC-NiCr coatings was
decreased by the decrease of the spray powder size by using a
pin-on-disk wear tester.
21)
Since the original particle size of our WC cermet powder
feedstock is very small (about 12 mm) and these small
particles are partially oxidized from surface by the spray
ame, it is expected that ne oxide particles were dispersed
in the coatings by thermal spray technique. The thermal spray
coatings might easily generate the small oxide wear debris by
wear than coatings made by other processes. It is well known
that the amount of oxide in the thermal spray coatings is
increased by the decrease of the spray powder size.
22)
As the oxidation of such thermal spray coating is promoted
by the heat treatment in air especially on the coating surface,
the small oxide wear debris could be obtained from an early
wear stage. We consider that this behaviour is similar to the
eect of shortening the severe-mild wear transition distance
by supplying the oxide particles to the rubbing surface during
sliding. This is one explanation why the severe-mild wear
transition was accelerated by heat treatment but more
detailed study is needed.
4. Conclusion
WC/20Cr
3
C
2
/7Ni cermet powder was HVOF sprayed
with combustion ames with dierent fuel-oxygen mixture
ratio. GS-HVOF was also employed to obtain dense coatings
with minimum oxidation. The results show that the coating
obtained by the fuel-rich ame was oxidized most. Heat
treatment in air increased the oxidation on the coating surface
signicantly.
Adhesive wear resistance of the coatings was evaluated by
the pin-on-disk wear tester. The result has demonstrated the
following.
(1) The specic wear rates of the cermet coatings were in
the order of 10
9
mm
2
/N, an order of magnitude
smaller than that of the iron pin. Only the coating
sprayed with the oxidizing ame exhibited the severe-
mild wear transition and the specic wear rate of the pin
was slightly above 10
7
mm
2
/N.
(2) Although the hardness of the coatings was not dierent
between the heat-treated GS coating and the untreated
GS coating, the specic wear rate of the heat-treated GS
coating was much lower to the extent that it could not be
measured. This was attributed to the eect of oxides
formed by the heat treatment, which should promote the
severe-mild wear transition by forming ne oxide
particles in between the sliding surfaces.
This might have a practical signicance it is important
for high wear resistance materials that mild wear
appears early.
Acknowledgement
We would like to thank Dr. T. Itsukaichi and Mr. S. Osawa
of Fujimi Inc. for supplying the cermet powder. Careful
preparation of the coating samples by Mr. M. Komatsu and
Mr. N. Kakeya of NIMS are also appreciated.
0
50
100
0 100 200 300 400 500
0
50
100
150
200
250
300
0 500 1000 1500 2000 2500 3000
Sliding distance, l /m
D
i
s
p
l
a
c
e
m
e
n
t
o
f
i
r
o
n
p
i
n
,
d
/
m
Gas shroud
Reducing flame
Oxidizing flame
Heat treatment
Chrome plating
Fig. 10 The displacement of iron pin.
Eect of Spray Condition and Heat Treatment on the Structure and Adhesive Wear Properties of WC Cermet Coatings 1675
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1676 Y. Ishikawa, J. Kawakita and S. Kuroda