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Article history:
Received 14 January 2014
Accepted 4 March 2014
Available online 12 March 2014
Co base powder (EWAC1006 EE) was modied with the addition of 20%WC and the same was further
modied by varying amounts of chromium carbide (0, 10 and 20 wt%) in order to develop three different
coatings. Microstructure, elemental mapping XRD, porosity and hardness analysis of the three coatings
was carried out. The effect of CrC concentration (C), load (L), abrasive size (A), sliding distance (S) and
temperature (T) on abrasive wear of these ame sprayed coatings was investigated by Response Surface
Methodology and an abrasive wear model was developed. A comparison of modeled and experimental
results showed 59% error.
& 2014 Elsevier Ltd. All rights reserved.
Keywords:
Coating
Abrasive wear
Microhardness
Response Surface Methodology (RSM)
1. Introduction
The progressive deterioration of metallic surfaces due to
various types of wear (abrasive, erosive, adhesive, corrosive and
chemical wear) in various industries (coal and hydro thermal
power plants, cement, automotive, chemical and cement industry)
leads to loss of plant operating efciency and frequent breakdown
of the components which in turn results in huge nancial losses to
the industry. The recognition of this fact has been the driving force
behind the continuing development of the surface modication
and surface coating technologies known as surface engineering.
The properties of these surface layers may be different from those
of the material as dictated by service requirements.
The cobalt base alloys have found a wide variety of tribological
applications for abrasive and adhesive wear resistance in many
industries such as aerospace, automotive, hydro and gas turbines
and cement industry. Some studies [16] report the effect of
processing techniques, carbide additions and their distribution
and post spray heat treatment on the hardness and abrasive wear
resistance of Co base coatings. The abrasive wear is inuenced by a
number of different factors such as the properties of the materials
(microstructure and hardness), the service conditions (applied
load and abrasive grit size) and environment (temperature and
humidity). High hardness and good resistance to abrasion of cobalt
based coatings are generally attributed to the presence of high
volume fraction of carbides. Increase in hardness of these alloys
with the addition of WC and TiC has been reported [7,8]. Maiti
et al. [9] reported that with addition of WC upto 20% in WCCoCr
coatings increases the hardness and abrasive wear rsistance and
further addition of WC increases hardness marginally. In the
present study, the Co base alloy was modied with WC and
varying amount of CrC additions (0%, 10% and 20%) to increase
the hardness and abrasive wear resistance of coatings.
In cement industry, various fans are used to transport alumina
and silica particles of 550 m size along with hot gases (temperature 393423 K). These solid particles travel along the fan blade
surface at a very low angle (o101). Abrasive wear has been
reported to simulate the low angle solid particle erosion conditions
[1013]. Cement industry is trying many types of coating materials
including cobalt base alloy. Therefore, in this work a cobalt base
alloy was selected for study and further developed for improved
abrasion and erosion performance. It has also been found from the
literature that most of the research on abrasive wear behavior of Co
base alloys was carried out considering single dimensional aspect of
applied wear conditions such as abrasive grit size and load only.
Data generated using traditional method of research using single
factor effect is valuable and detailed, but fails to indicate the effect
of their interactions of various test parameters on abrasive wear.
Therefore, a number of statistical methods have recently been
implemented in wear studies. These methods share the advantage
of facilitating research into the effects of different factors and
their interactions (combined effect), by limiting the number of
tests. Hence in this study an attempt has been made to study
the independent as well as combined effect of the factors
using fractional factorial design (Response Surface Methodology).
40
The average of 25 areas of each coating has been used for porosity
measurement. Vickers hardness of the coating was measured using a
load of 5 kg and average of six readings of the coating was used for
study purpose. Scanning electron microscopy of the worn surfaces of
coatings was also carried out to identify the material removal
mechanisms under abrasive wear conditions.
2. Experimental procedure
Cr
Si
Fe
_
_
0.40.6 Balance
2830 56 0.20.5 _
Co
Coded value
_
0.40.8
Balance 0.50.7
Table 2
Flame spray parameters.
Parameters
Value
18 mm
120 mm/min
651
Table 3
Various factors and their levels.
Factor
Designation
Lower level
Middle level
Upper level
C
L
A
S
T
0 ( 1)
5 ( 1)
20 72a {500} ( 1)
25 ( 1)
50 ( 1)
10 (0)
15 (0)
60 74a{220} (0)
55 (0)
100 (0)
20 ( 1)
25 ( 1)
1007 5a {120} ( 1)
85 ( 1)
150 ( 1)
As given by manufacturer.
41
Table 4
Design matrix and various factors with their actual and coded values (in parentheses).
Run no.
Composition (C)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
0
20
0
10
10
0
10
10
20
10
20
10
0
20
20
0
0
0
10
0
10
20
20
20
20
10
0
10
10
10
( 1)
( 1)
( 1)
(0)
(0)
( 1)
(0)
(0)
( 1)
(0)
( 1)
(0)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
(0)
( 1)
(0)
( 1)
( 1)
( 1)
( 1)
(0)
( 1)
(0)
(0)
(0)
Load (L)
25
25
15
25
15
25
15
5
25
15
15
15
5
25
5
25
5
5
15
25
15
5
25
5
5
15
5
15
15
15
( 1)
( 1)
(0)
( 1)
(0)
( 1)
(0)
( 1)
( 1)
(0)
(0)
(0)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
(0)
( 1)
(0)
( 1)
( 1)
( 1)
( 1)
(0)
( 1)
(0)
(0)
(0)
( 1)
( 1)
(0)
(0)
( 1)
( 1)
( 1)
(0)
( 1)
(0)
(0)
(0)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
(0)
( 1)
(0)
( 1)
( 1)
( 1)
( 1)
(0)
( 1)
(0)
(0)
(0)
( 1)
( 1)
(0)
(0)
(0)
( 1)
(0)
(0)
( 1)
(0)
(0)
(0)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
(0)
( 1)
(0)
(0)
(0)
Temperature (T)
50
50
100
100
100
50
100
100
50
150
100
100
150
150
50
150
50
150
100
150
100
150
150
50
150
50
50
100
100
100
( 1)
( 1)
(0)
(0)
(0)
( 1)
(0)
(0)
( 1)
( 1)
(0)
(0)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
(0)
( 1)
(0)
( 1)
( 1)
( 1)
( 1)
( 1)
( 1)
(0)
(0)
(0)
carbides C are rich in Cr and contain 52% Cr, 15% W, 13% Co, 7% C
besides small amounts of Ni and Fe ( o5%) (wt%) as shown by the
EDAX analysis (Fig. 1d).
The microstructures and EDAX analysis of 10 wt% chromium
carbide (not shown for brevity) and 20 wt% chromium carbide
coatings are shown in Fig. 2(ad). Both these chromium carbide
modied coatings exhibited features similar to that of 0 wt%
chromium carbide coating except that compositions of eutectic
and carbides were different. The quantitative EDAX analysis showed
that the wt% of Co (E30 wt%) is same in the eutectic matrix of all
the three coatings (0 wt% chromium carbide, 10 wt% chromium
carbide and 20 wt% chromium carbide) and it is uniformly distributed in the eutectic matrix as shown in elemental maps (Fig. 3a2, b-2 and c-2). These results are in agreement with ndings of
Shetty et al. [22] as they reported that the eutectic matrix is rich in
Co containing various types of carbides, which are uniformly
distributed in the matrix. The other elements such as Ni, Fe and
Cr are also uniformly distributed in the eutectic matrix (Fig. 3ac).
However, wt% of Cr increased from 8 to 14 wt% with the addition of
chromium carbide. Some of the carbide particles appear darker in
SEM micrographs as can be seen in Figs. 1 and 2. This observation is
also in line with the ndings of Shetty et al. [22].
Image analyses of three coatings viz. 0 wt% chromium carbide,
10 wt% chromium carbide and 20 wt% chromium carbide was
carried out to determine the volume fraction of eutectic, W
dominated and Cr dominated carbides (A, B and C respectively). The volume fraction of eutectic A was found as 72.1%,
65.7% and 46.1% respectively in 0% chromium carbide, 10% chromium carbide and 20% chromium carbide coatings. The volume
fraction of W dominated carbides B was found as 13.8%, 17% and
27.5% respectively, whereas the Cr dominated carbides C was
observed as 14.1%, 18.3% and 26.4% respectively in the three
coatings (0 wt% chromium carbide, 10 wt% chromium carbide
and 20 wt% chromium carbide).
42
Cr dominated
Carbides C
W dominated
carbides B
Eutectic A
Eutectic
A
W dominated
carbides B
Cr dominated
Carbides C
Fig. 1. Microstructure and EDAX analysis of 0 wt% chromium carbide coating (a) microstructure of coating, (b) EDAX analysis of eutectic, (c) EDAX analysis of W dominated
carbide and (d) EDAX analysis of Cr dominated carbide.
The Vickers hardness (Hv5) and porosity (%) of the three coatings
with varying wt% of chromium carbide (0 wt% chromium carbide,
10 wt% chromium carbide and 20 wt% chromium carbide) are
shown in Fig. 7(a) and (b) respectively. Vickers hardness of three
coatings was measured using a normal load of 5 kg and average
value of six readings of hardness of the coating cross-section has
been used for study. The average Vickers hardness (Hv5) of three
coatings (0 wt% chromium carbide, 10 wt% chromium carbide and
20 wt% chromium carbide) was found to be 696786 Hv5,
741795 Hv5 and 7867112 Hv5 respectively (Fig. 7a). The average
hardness of 20 wt% chromium carbide coating was found higher
(786 Hv5) as compared to 0 wt% chromium carbide (696 Hv5) and
10 wt% chromium carbide (741 Hv5) coatings, however, there was a
more scatter in hardness of 20 wt% chromium carbide coating as
compared to 0 wt% chromium carbide and 10% chromium carbide
coatings may be due to higher porosity (Fig. 7b).
The higher hardness of 10 wt% chromium carbide coating as
compared to 0 wt% chromium carbide is due to formation of
Cr23C6 carbides and intemetallic compound Co7W6 as detected
by XRD analysis (Fig. 5). The highest hardness of 20 wt% chromium
carbide coating as compared to other two (0 wt% chromium
carbide and 10 wt% chromium carbide) is mainly due to formation
of Cr7C3 carbides as detected by XRD analysis (Fig. 6). The formation
43
W dominated
carbides B
Eutectic A
Eutectic A
Cr dominated
Carbides C
W dominated
Cr dominated
carbides B
Carbides C
Fig. 2. Microstructure and EDAX analysis of 20 wt% chromium carbide coating (a) microstructure of coating, (b) EDAX analysis of eutectic, (c) EDAX analysis of W dominated
carbide and (d) EDAX analysis of Cr dominated carbide.
for the abrasive wear. In applying the RSM the dependent variable
(abrasive wear) is viewed as a surface to which the model is tted.
Evaluation of the parametric effects on the response (abrasive
wear) was done by considering a second order polynomial
response surface mathematical model given by:
k
i1
i1
k1
Wr b0 bi xi bii x2i
bij xi xj r
i 1 j i1
44
3 a-1
3 b-1
3 c-1
Area C
3 a-2
3 c-2
3 b-2
Area C
Co
3 a-3
Co
Co
3 b-3
3 c-3
Area C
Cr
3 a-4
Cr
Cr
3 b-4
3 c-4
Area C
Ni
3 a-5
Ni
Ni
3 c-5
3 b-5
Area C
Fe
3 a-6
Fe
Fe
3 b-6
3 c-6
Area C
Fig. 3. Elemental maps showing the distribution of Co, Cr, Ni, Fe, and C in (a) 0 wt% chromium carbide, (b) 10 wt% chromium carbide and (c) 20 wt% chromium carbide
coatings.
160
Relative Intensity
140
1- Ni-Cr-Fe-C 3- Ni W
5- Fe C
7- NiO
2- M C
6- Fe
8- Cr O
4- CoWSi
1, 3,5, 6
120
1, 2, 3
8 4
100
45
5
6
8:42 103 AS 7 R
80
60
40
50
60
70
80
90
100
Diffraction angle 2
Fig. 4. XRD spectrum showing various phases in 0 wt% chromium carbide coating.
1- Cr C
2- Cr C
3- Co W
4- WSi
5- FeNi
Relative Intensity
160
1
140
1, 2, 3, 4,
1
1
120
1, 2, 5
100
4
1
80
60
40
40
50
60
70
80
90
100
Diffraction angle 2
Fig. 5. XRD spectrum showing various phases in 10 wt% chromium carbide coating.
220
1- Cr C
2- Co W C
3- Ni Si
4- Fe C
5- FeNi
Relative Intensity
200
180
1, 2, 3, 4
160
140
120
3, 5
100
80
60
40
50
60
70
80
90
100
Diffraction angle 2
800
780
760
740
720
700
680
660
640
786112
74195
Porosity (%)
Fig. 6. XRD spectrum showing various phases in 20 wt% chromium carbide coating.
69686
0 wt.%
10 wt.%
20 wt.%
10
9
8
7
6
5
4
3
2
1
0
8.6
9.2
7.7
0 wt.%
10 wt.%
20 wt.%
Fig. 7. Effect of chromium carbide addition in 100620 wt%WC powder coating on (a) hardness (Hv5) and (b) porosity (%).
46
Table 5
Analysis of variance (ANOVA).
Source
Sum squares
Degrees of freedom
Mean square
F value
Prob.4F
Model
CompositionC
LoadL
Abrasive sizeA
Sliding distanceS
TemperatureT
Interaction CL
Interaction CT
Interaction LA
Interaction LS
Interaction AS
Residual error
Lack of t
Pure error
0.013
4.25 10 4
2.850 10 3
1.703 10 3
4.431 10 3
9.800 10 7
1.742 10 4
2.92 10 4
4.752 10 4
1.056 10 3
1.136 10 3
4.477 10 4
4.358 10 4
1.189 10 5
11
1
1
1
1
1
1
1
1
1
1
18
15
3
1.21 10 3
4.25 10 4
2.850 10 3
1.703 10 3
4.431 10 3
9.800 10 7
1.742 10 4
2.92 10 4
4.752 10 4
1.056 10 3
1.136 10 3
2.487 10 5
2.906 10 5
3.963 10 6
48.45
17.10
114.58
68.48
178.12
0.039
7.00
11.76
19.11
42.46
45.66
o 0.0001
0.0006
o 0.0001
o 0.0001
o 0.0001
0.8449
0.0164
0.0030
0.0004
o 0.0001
o 0.0001
Signicant
0.0632
Not signicant
7.33
Table 6
Conrmations test results.
Composition,
C (% CrC)
Load,
L (N)
Sliding distance,
S (m)
Temperature,
T (1C)
Modeled abrasive
wear (g)
Experimental abrasive
wear (g)
Error
(%)
0 ( 1)
10 (0)
20 ( 1)
15 (0)
15 (0)
15 (0)
42 72 {320} ( 0.5)
42 72 {320} ( 0.5)
42 72 {320} ( 0.5)
70 ( 0.5)
70 ( 0.5)
70 ( 0.5)
100 ( 0.5)
100 ( 0.5)
100 ( 0.5)
0.0238
0.019
0.0141
0.0250
0.0173
0.0152
4.8
8.95
7.24
0.104
0.0612
0.0787
0.0458
Abrasive wear, g
Abrasive wear, g
0.0534
0.0281
0.0028
0.0304
0.0150
-0.0005
0.00
5.00
10.00
15.00
5.00
20.00
10.00
15.00
20.00
25.00
Load (L), N
0.0612
0.104
0.0459
0.0787
Abrasive wear, g
Abrasive wear, g
47
0.0306
0.0153
0.0000
0.0534
0.0281
0.0028
20.00
40.00
60.00
80.00
100.00
25.00
40.00
55.00
70.00
85.00
Abrasive wear, g
0.104
0.0787
0.0534
0.0281
0.0028
50.00
75.00
100.00
125.00
150.00
Temperature (T),C
Fig. 8. Effects of individual factors such as (a) % CrC-concentration, (b) load, (c) abrasive size (d) sliding distance and (e) temperature on abrasive wear.
0.0612
0.0612
0.0459
0.0459
Abrasive wear, g
Abrasive wear, g
48
0.0306
0.0153
0.0000
0.0306
0.0153
0.0000
25.00
150.00
20.00
20.00
),
(L
0.0612
0.0612
0.0459
0.0459
Abrasive wear, g
Abrasive wear, g
5.00 0.00
0.0306
0.0153
0.0000
),
(C
n
tio
5.00
si CrC
o
p
m t.%
Co w
15.00
100.00
on
iti rC
5.00
s
po C
m t.%
o
w
C
10.00
10.00
re
tu
ra
pe
m ), C
Te (T
ad
Lo
15.00
20.00
125.00
),
(C
15.00
10.00
75.00
50.00 0.00
0.0306
0.0153
0.0000
85.00
100.00
ze
si
ve m
si
ra ),
Ab (A
20.00
60.00
15.00
40.00
10.00
20.00 5.00
ad
Lo
),
(L
ce
an
st
Di
g ), m
in
id (S
Sl
25.00
80.00
25.00
70.00
20.00
55.00
15.00
40.00
25.00 5.00
10.00
ad
Lo
),
(L
Abrasive wear, g
0.0612
0.0459
0.0306
0.0153
0.0000
85.00
Sl
id 70.00
in
g 55.00
(S Dis
),
40.00
m tan
ce 25.00
100.00
80.00
e
siz
e
40.00
siv m
ra ),
b
20.00
A (A
60.00
Fig. 9. Effects of interactions (a) composition-load, (b) composition-temperature, (c) load-abrasive size, (d) load-sliding distance and (e) abrasive size and sliding distance on
abrasive wear.
49
Sliding Direction
Ploughing
Fig. 10. SEM micrographs of worn surfaces (a) 0 wt% chromium carbide, (b) 10 wt% chromium carbide and (c) 20 wt% chromium carbide.
4. Conclusions
The following conclusions can be drawn from the present
study:
1. The hardness increases with the increase in chromium carbide
concentration. The maximum hardness was obtained with
20 wt% chromium carbide. The increase in hardness is due to
formation of new phases and inetrmetallic compounds.
2. Response Surface Methodology (RSM) with fractional factorial
design approach is an excellent tool, which can be successfully
used to develop an empirical equation for the prediction and
understanding of wear behavior of coatings in terms of individual factors (C, L, A, S and T) as well as in terms of the combined
effects (CL, CT, LA, LS and AS) of various factors.
3. The load and sliding distance have a more severe effect on
abrasive wear of the coating as compared to abrasive size.
4. Interaction effects of various factors on abrasive wear is almost
of same order less than their main factor effects. The interaction effect of abrasive size-sliding distance (AS) is considerably
higher than load-abrasive size (LA). Increasing (%) CrC concentration; reducing load, abrasive size and sliding distance minimize the abrasive wear signicantly.
5. Increase in chromium carbide concentration increases the
abrasive wear resistance of the coatings. Abrasive wear rate
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