Fatigue Behaviour of High Velocity Oxy-Fuel Coatings on Medium Carbon Steel

Fatigue Behaviour of High Velocity Oxy-Fuel Coatings on Medium Carbon Steel
  IJETT-book-cover           
  
© 2021 by IJETT Journal
Volume-69 Issue-6
Year of Publication : 2021
Authors : M. A. M. Halmi, M. A. Harimon, A. E. Ismail, D. Chue
DOI :  10.14445/22315381/IJETT-V69I6P209

How to Cite?

M. A. M. Halmi, M. A. Harimon, A. E. Ismail, D. Chue, "Fatigue Behaviour of High Velocity Oxy-Fuel Coatings on Medium Carbon Steel," International Journal of Engineering Trends and Technology, vol. 69, no. 6, pp. 56-70, 2021. Crossref, https://doi.org/10.14445/22315381/IJETT-V69I6P209

Abstract
Nowadays, the application of high-velocity oxy-fuel (HVOF) thermal spraying coating is widely used in various industries. This is due to its ability to improve the wear, erosion, and corrosion resistance of components. However, by taking consideration of fatigue behaviour into cognisance, the consequence of the HVOF thermal spraying coating on the components remains debatable. In this research, the fatigue behaviour of the uncoated steel, WC-12Co coated steel, and WC-10Ni coated steel were investigated. At first, the tensile test was conducted on the S50C steel to determine its yield strength. The yield strength was then being applied as a benchmark in a staircase method to set the stress amplitudes for the fatigue test. Fatigue tests were performed under the stress ratio, R=-1, by tension-compression cyclic loading (sine wave) with a frequency of 20 Hz according to ASTM-E466. The results showed that the HVOF decreased the tensile and yield strength by 8.9% and 9.5%, respectively. Similar behaviours are shown by the fatigue properties, as the HVOF coated steel reduced the fatigue strength’s by 17%. The decrement of the fatigue strength was mainly due to the increment of the substrate´s grain size, which results from the high flame temperature (2750?C) of the HVOF process.

Keywords
fatigue, HVOF, S50C carbon steel, WC-12Co, WC-10Ni.

Reference
[1] R. J. Talib, S. Saad, M. R. M. Toff, and H. Hashim, Thermal spray coating technology - a review,” Solid State Sci. Technol., 11(1)(2003) 109–117.
[2] M. Oksa, E. Turunen, T. Suhonen, T. Varis, and S.-P. Hannula, Optimization and characterization of high-velocity oxy-fuel sprayed coatings: techniques, materials, and applications, Coatings, 1(1)(2011) 17–52.
[3] P. K. Katiyar, P. K. Singh, R. Singh, and A. L. Kumar, Modes of failure of cemented tungsten carbide tool bits (WC/Co) : a study of wear parts, Int. J. Refract. Met. Hard Mater., 54(2016) 27–38.
[4] I. Hulka, D. Utu, V. A. Serban, M. L. Dan, V. Matikainen, and P. Vuoristo, Corrosion Behavior of WC-Ni Coatings Deposited by Different Thermal Spraying Methods, 60(74) 2015.
[5] R. C. Souza, M. P. Nascimento, H. J. C. Voorwald, and W. L. Pigatin, The effect of WC-17Co thermal spray coating by HVOF and hard chromium electroplating on the fatigue life and abrasive wear resistance of AISI 4340 high strength steel, Corros. Rev., 21(1)(2003) 75–96.
[6] G. S. Junior, H. J. C. Voorwald, L. F. S. Vieira, M. O. H. Cioffi, and R. G. Bonora, Evaluation of WC-10Ni thermal spray coating with shot peening on the fatigue strength of AISI 4340 steel, Procedia Eng., 2(1)(2010) 649–656.
[7] J. G. La Barbera-Sosa et al., Fatigue behavior of a structural steel coated with a WC-10Co-4Cr/Colmonoy 88 deposit by HVOF thermal spraying, Surf. Coatings Technol., 220(2013) 248–256.
[8] R. G. Bonora, H. J. C. Voorwald, M. O. H. Cioffi, G. S. Junior, and L. F. V. Santos, Fatigue in AISI 4340 steel thermal spray coating by HVOF for aeronautic application, Procedia Eng., 2(1)(2010) 1617–1623
[9] E. S. Puchi-Cabrera et al., Fatigue behavior of an SAE 1045 steel coated with Colmonoy 88 alloy deposited by HVOF thermal spray, Surf. Coatings Technol., 205(4)(2010) 1119–1126.
[10] A. C. Murariu, A. V. Cernescu, and I. A. Perianu, The effect of saline environment on the fatigue behaviour of HVOF-sprayed WC–CrC–Ni coatings, Surf. Eng., 34(10)(2018) 755–761.
[11] E. F. Rejda, D. F. Socie, and B. Beardsley, Fatigue behavior of a plasma-sprayed 8%Y2O3-ZrO2thermal barrier coating, Fatigue Fract. Eng. Mater. Struct., 20(7)(1997) 1043–1050.
[12] M. P. Nascimento, R. C. Souza, I. M. Miguel, W. L. Pigatin, and H. J. C. Voorwald, Effects of tungsten carbide thermal spray coating by HP/HVOF and hard chromium electroplating on AISI 4340 high strength steel, Surf. Coatings Technol., 138(2–3)(2001) 113–124.
[13] H. J. C. Voorwald, L. F. S. Vieira, and M. O. H. Cioffi, Evaluation of WC-10Ni thermal spraying coating by HVOF on the fatigue and corrosion AISI 4340 steel, Procedia Eng., 2(1)(2010) 331–340.
[14] T. C. Totemeier, R. N. Wright, and W. D. Swank, Mechanical and physical properties of high-velocity oxy-fuel-sprayed iron aluminide coatings, Metall. Mater. Trans. A, 34A(10)(2003) 2223–2231.
[15] A. Ibrahim and C. C. Berndt, The effect of high-velocity oxygen fuel, thermally sprayed WC-Co coatings on the high-cycle fatigue of aluminium alloy and steel, J. Mater. Sci., 33(12)(1998) 3095–3100.
[16] E. S. Puchi-Cabrera et al., Fatigue behavior of AA7075-T6 aluminum alloy coated with a WC-10Co-4Cr cermet by HVOF thermal spray, Surf. Coatings Technol., 220(2013) 122–130.
[17] H. Okada, Y. Uematsu, and K. Tokaji, Fatigue behavior in AZ80A magnesium alloy with DLC/thermally splayed WC-12Co hybrid coating, Procedia Eng., 2(1)(2010) 283–290.
[18] J. Kawakita, S. Kuroda, and T. Kodama, Evaluation of through-porosity of HVOF sprayed coating, Surf. Coatings Technol., 166(1)(2003) 17–23.
[19] R. Nieminen, P. Vuoristo, K. Niemi, T. Mäntylä, and G. Barbezat, Rolling contact fatigue failure mechanisms in plasma and HVOF sprayed WC-Co coatings, Wear, 212(1)(1997) 66–77.
[20] N. A. Ahmad, Z. Kamdi, A. Latif, and M. Tobi, Wear and corrosion behavior of tungsten carbide-based coating on carbon steel, Int. J. Integr. Eng.,10(4)(2018) 119–125.
[21] ASTM Standard E8/E8M. Standard Test Methods for Tension Testing of Metallic Materials. West Conshohocken: ASTM International, 2009.
[22] ASTM Standard E466. Conducting Force Controlled Constant Amplitude Axial Fatigue Tests of Metallic Materials. West Conshohocken: ASTM International, 2015.
[23] T. A. Ben Mahmud, G. C. Saha, and T. I. Khan, Mechanical property changes in HVOF sprayed nano-structured WC-17wt.%Ni(80/20)Cr coating with varying substrate roughness, IOP Conf. Ser. Mater. Sci. Eng., 60(2014) 1–8.
[24] S. Banerjee, P. C. Chakraborti, and S. K. Saha, An automated methodology for grain segmentation and grain size measurement from optical micrographs,” Measurement, 140(2019)142–150.
[25] A. A. Azeez, Fatigue Failure and Testing Methods, Dissertation of Bachelor, HAMK University of applied sciences, 2013.
[26] Y. Murakami, Metal Fatigue: Effects of Small Defects and Nonmetallic Inclusions. Kyushu University, Japan: Elsevier, 2002.
[27] B. Wielage, H. Pokhmurska, A. Wank, G. Reisel, S. Steinhaeuser, and M. Woezel, Influence of thermal spraying method on the properties of tungsten carbide coatings, in Proceedings of the Conference on Modern Wear and Corrosion Resistant Coatings Obtained by Thermal Spraying, (2003) 20–21.
[28] L. Gu, J. Huang, Y. Tang, C. Xie, and S. Gao, Influence of different post treatments on microstructure and properties of WC-Co cemented carbides, J. Alloys Compd., 620(2015) 116–119.
[29] J. M. Guilemany, J. Nutting, J. R. Miguel, and Z. Dong, Microstructure formation of HVOF sprayed WC-Ni coatings deposited on low alloy steel, Mater. Manuf. Process., 12(5)(1997) 901–909.
[30] Y. M. Zou, Y. S. Wu, J. Z. Wang, Z. G. Qiu, and D. C. Zeng, Preparation, mechanical properties and cyclic oxidation behavior of the nanostructured NiCrCoAlY-TiB2 coating, Ceram. Int., 44(16)(2018) 19362–19369.
[31] D. Tejero-Martin, Z. Pala, S. Rushworth, and T. Hussain, Splat formation and microstructure of solution precursor thermal sprayed Nb-doped titanium oxide coatings, Ceram. Int., 46(4)(2020) 5098–5108.
[32] J. G. La Barbera-Sosa et al., Microstructural and mechanical characterization of Ni-base thermal spray coatings deposited by HVOF, Surf. Coatings Technol., 202(18)(2008) 4552–4559.
[33] N. W. Satya and W. Winarto, Microstructure, hardness, and surface cracks evaluation of HVOF-sprayed stellite-1 coating applied on steam turbine blade, Key Eng. Mater., 833 KEM(2020) 80–84.
[34] G. Bolelli, L. Lusvarghi, and M. Barletta, HVOF-sprayed WC-CoCr coatings on Al alloy: Effect of the coating thickness on the tribological properties, Wear, 267(5–8) 944–953.
[35] M. Jadidi, S. Moghtadernejad, and A. Dolatabadi, A comprehensive review on fluid dynamics and transport of suspension/liquid droplets and particles in High-Velocity Oxygen-Fuel (HVOF) thermal spray, Coatings, 5(4)(2015) 576–645.
[36] W. D. Callister, Materials science and engineering : An introduction, 7th ed. New York: John Wiley & Sons, 2007.
[37] A. W. Zia, Z. Zhou, P. W. Shum, and L. K. Y. Li, The effect of two-step heat treatment on hardness, fracture toughness, and wear of different biased diamond-like carbon coatings, Surf. Coatings Technol., 320(2017) 118–125.
[38] V. K. Satish, Chapter 8. Failure, in Material Science, Dept. of Mechanical Engineering, Indian Institute of Science, Bangalore, 2009.
[39] C. Pandey, A. Giri, and M. M. Mahapatra, Evolution of phases in P91 steel in various heat treatment conditions and their effect on microstructure stability and mechanical properties, Mater. Sci. Eng. A, 664(2016) 58–74.
[40] S. Yan and X. Zhao, A fracture criterion for fracture simulation of ductile metals based on micro-mechanisms, Theor. Appl. Fract. Mech., 95(2018) 127–142.
[41] R. I. Stephens, A. Fatemi, R. R. Stephens, and H. O. Fuchs, Metal Fatigue in Engineering, 2nd edition. Wiley Interscience, 2000.
[42] S. Kalpakjian, Manufacturing Engineering and Technology, 3rd ed. Addison-Wesley Publishing Co., 1995.
[43] R. C. Juvinall and K. M. Marshek, Fundamentals of Machine Component Design, 2nd ed. New York: John Wiley and Sons, 1991.
[44] J. Siegl, I. Nedbal, and J. Kunz, Fractographic study of fatigue processes, in Fracture Damage of Structural Parts, (2004) 165–172.
[45] G. Jacoby, Fractographic methods in fatigue research, Exp. Mech., 5(3)(1965) 65–82.
[46] L. O. A. Affonso, Machinery Failure Analysis Handbook: Sustain Your Operations and Maximize Uptime, vol. 1. 2007.
[47] G. A. Pantazopoulos, A short review on fracture mechanisms of mechanical components operated under industrial process conditions: Fractographic analysis and selected prevention strategies, Metals (Basel)., 9(2)(2019).
[48] R. W. Hertzberg, Deformation anf Fracture Mechanics of Engineering Materials, 4th ed. New York: John Wiley and Sons, 1996.