Sliding Wear Behavior as a Criterion for Replacement of Chromium Electroplate by Tungsten Carbide (WC) Thermal Spray Coatings in Aircraft Applications

2000 ◽  
Author(s):  
A.C. Savarimuthu ◽  
I. Megat ◽  
H.F. Taber ◽  
J.R. Shadley ◽  
E.F. Rybicki ◽  
...  
Keyword(s):  
Tungsten Carbide ◽  
Thermal Spray ◽  
Sliding Wear ◽  
Wear Behavior ◽  
Sem Analysis ◽  
Thermal Spray Coatings ◽  
Commercial Aircraft ◽  
Spray Coatings ◽  
Compressive Stresses ◽  
Fatigue Characteristics

Abstract Tungsten Carbide (WC) thermal spray coatings have had increased acceptance in commercial aircraft applications driven by the desire to replace chromium electroplate due to environmental and economic considerations [1]. In order to confidently replace chromium electroplate by WC thermal spray coatings, evaluation of wear and fatigue characteristics of the WC thermal spray coatings is necessary. For WC thermal spray coatings to replace chromium electroplate in aircraft applications, the coatings must demonstrate wear and fatigue characteristics as good as or better than those of chrome plating. Previous research in this area has shown that the fatigue life of the WC thermal spray coatings can be improved by inducing compressive stresses in the coating. This paper compares the wear characteristics of several types of WC thermal spray coatings with those of chromium electroplate in sliding wear tests following the "block-on-ring" procedures described in ASTM G77 standard. Wear results are interpreted in terms of coating residual stresses and in terms of X-ray diffraction and Scanning Electron Microscope (SEM) analysis.

Sliding Wear Behavior of Tungsten Carbide Thermal Spray Coatings for Replacement of Chromium Electroplate in Aircraft Applications

2001 ◽  
Vol 10 (3) ◽  
pp. 502-510 ◽  
Author(s):  
A.C. Savarimuthu ◽  
H.F. Taber ◽  
I. Megat ◽  
J.R. Shadley ◽  
E.F. Rybicki ◽  
...  
Keyword(s):  
Tungsten Carbide ◽  
Thermal Spray ◽  
Sliding Wear ◽  
Wear Behavior ◽  
Thermal Spray Coatings ◽  
Spray Coatings

scholarly journals Sliding Wear of Conventional and Suspension Sprayed Nanocomposite WC-Co Coatings: An Invited Review

2021 ◽  
Author(s):  
R. Ahmed ◽  
O. Ali ◽  
C. C. Berndt ◽  
A. Fardan
Keyword(s):  
Wear Rate ◽  
Thermal Spray ◽  
Sliding Wear ◽  
Failure Modes ◽  
Thermal Spray Coatings ◽  
Annual Growth Rate ◽  
Total Energy Consumption ◽  
Wear Performance ◽  
Wear Rates ◽  
Spray Coatings

AbstractThe global thermal spray coatings market was valued at USD 10.1 billion in 2019 and is expected to grow at a compound annual growth rate of 3.9% from 2020 to 2027. Carbide coatings form an essential segment of this market and provide cost-effective and environmental friendly tribological solutions for applications in aerospace, industrial gas turbine, automotive, printing, oil and gas, steel, and pulp and paper industries. Almost 23% of the world’s total energy consumption originates from tribological contacts. Thermal spray WC-Co coatings provide excellent wear resistance for industrial applications in sliding and rolling contacts. Some of these applications in abrasive, sliding and erosive conditions include sink rolls in zinc pots, conveyor screws, pump housings, impeller shafts, aircraft flap tracks, cam followers and expansion joints. These coatings are considered as a replacement of the hazardous chrome plating for tribological applications. The microstructure of thermal spray coatings is however complex, and the wear mechanisms and wear rates vary significantly when compared to cemented WC-Co carbides or vapour deposition WC coatings. This paper provides an expert review of the tribological considerations that dictate the sliding wear performance of thermal spray WC-Co coatings. Structure–property relationships and failure modes are discussed to grasp the design aspects of WC-Co coatings for tribological applications. Recent developments of suspension sprayed nanocomposite coatings are compared with conventional coatings in terms of performance and failure mechanisms. The dependency of coating microstructure, binder material, carbide size, fracture toughness, post-treatment and hardness on sliding wear performance and test methodology is discussed. Semiempirical mathematical models of wear rate related to the influence of tribological test conditions and coating characteristics are analysed for sliding contacts. Finally, advances for numerical modelling of sliding wear rate are discussed.

Effect of thermal spray coatings on wear behavior of high tensile steel applicable for tiller blades

2017 ◽  
Vol 4 (2) ◽  
pp. 95-103 ◽  
Author(s):  
Amardeep S. Kang ◽  
Jasmaninder S. Grewal ◽  
Gurmeet S. Cheema
Keyword(s):  
Thermal Spray ◽  
Wear Behavior ◽  
Thermal Spray Coatings ◽  
Spray Coatings

scholarly journals Combating Wear of ASTM A36 Steel by Surface Modification Using Thermally Sprayed Cermet Coatings

2016 ◽  
Vol 2016 ◽  
pp. 1-10 ◽  
Author(s):  
Vineet Shibe ◽  
Vikas Chawla
Keyword(s):  
Thermal Spray ◽  
Sliding Wear ◽  
Thermal Spray Coatings ◽  
Wear Performance ◽  
Cermet Coatings ◽  
Spray Coatings ◽  
Spray Technique ◽  
A36 Steel ◽  
Thermally Sprayed ◽  
Better Than

Thermal spray coatings can be applied economically on machine parts to enhance their requisite surface properties like wear, corrosion, erosion resistance, and so forth. Detonation gun (D-Gun) thermal spray coatings can be applied on the surface of carbon steels to improve their wear resistance. In the present study, alloy powder cermet coatings WC-12% Co and Cr3C2-25% NiCr have been deposited on ASTM A36 steel with D-Gun thermal spray technique. Sliding wear behavior of uncoated ASTM A36 steel and D-Gun sprayed WC-12% Co and Cr3C2-25% NiCr coatings on base material is observed on a Pin-On-Disc Wear Tester. Sliding wear performance of WC-12% Co coating is found to be better than the Cr3C2-25% NiCr coating. Wear performance of both these cermet coatings is found to be better than uncoated ASTM A36 steel. Thermally sprayed WC-12% Co and Cr3C2-25% NiCr cermet coatings using D-Gun thermal spray technique is found to be very useful in improving the sliding wear resistance of ASTM A36 steel.

Wear behavior of microwave-annealed and cryogenically treated thermal spray coatings: A comparative evaluation

2020 ◽  
Vol 33 ◽  
pp. 5348-5353
Author(s):  
Abhishek Babu ◽  
H.S. Arora ◽  
R.B. Nair ◽  
I. Chakraborty ◽  
A. Chauhan ◽  
...  
Keyword(s):  
Thermal Spray ◽  
Comparative Evaluation ◽  
Wear Behavior ◽  
Thermal Spray Coatings ◽  
Spray Coatings

Fatigue Life in Bending and Coatings Residual Stress in Tungsten Carbide Thermal Spray Coatings

1997 ◽  
Author(s):  
R.T.R. McGrann ◽  
J.R. Shadley ◽  
E.F. Rybicki ◽  
D.J. Graving ◽  
B.E. Badger ◽  
...  
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Tungsten Carbide ◽  
Thermal Spray ◽  
Thermal Spray Coatings ◽  
Chrome Plating ◽  
Spray Coatings ◽  
Wear Protection ◽  
Carbide Coatings ◽  
Flat Beam

Abstract Tungsten caibide (WC) thermal spray coatings are being used for wear protection on selected components of aircraft. Tungsten carbide coatings are being used on aircraft flap tracks and fan and compressor blade mid-span dampers. However, a larger use of tungsten carbide coatings is being considered for other commercial aircraft applications where it would be used as a replacement for chrome plating. For instance, WC coatings are currently being tested on aircraft landing gear parts. One factor that affects the suitability of WC coatings for these applications is the fatigue life of the coated part. Coatings, whether chrome plating or thermal spray coating, can reduce the fatigue life of the part compared to an uncoated part. This study compares the fatigue life of uncoated 6061 aluminum specimens to the fatigue life of WC thermal sprayed coated 6061 aluminum specimens. The relation between the residual stress level in the coating and the fatigue life of the specimens is also investigated. Fatigue tests were run on cantilever flat beam specimens that were coated on one side. Specimens were cycled in bending so that the coatings experienced tensile fatigue stresses. Residual stress levels for each type of coating were determined using the Modified Layer Removal Method on specimens processed along with the cantilever flat beam specimens. Test results show that the fatigue life of the WC coated specimens is directly related to the level of compressive residual stress in the coating.

Wear Behavior of Thermal Spray Coatings on Rotavator Blades

2011 ◽  
Vol 21 (2) ◽  
pp. 355-359 ◽  
Author(s):  
Amardeep Singh Kang ◽  
Jasmaninder Singh Grewal ◽  
Deepak Jain ◽  
Shivani Kang
Keyword(s):  
Thermal Spray ◽  
Wear Behavior ◽  
Thermal Spray Coatings ◽  
Spray Coatings

USE OF IBA TECHNIQUES TO CHARACTERIZE HIGH VELOCITY THERMAL SPRAY COATINGS

2001 ◽  
Vol 15 (28n29) ◽  
pp. 1428-1436 ◽  
Author(s):  
W. TROMPETTER ◽  
A. MARKWITZ ◽  
M. HYLAND
Keyword(s):  
Thermal Spray ◽  
High Velocity ◽  
Sliding Wear ◽  
Thermal Spraying ◽  
Thermal Spray Coatings ◽  
Spray Coatings ◽  
The Past ◽  
Composition And Structure ◽  
Wide Range ◽  
Sprayed Coating

Spray coatings are being used in an increasingly wide range of industries to improve the abrasive, erosive and sliding wear of machine components. Over the past decade industries have moved to the application of supersonic high velocity thermal spray techniques. These coating techniques produce superior coating quality in comparison to other traditional techniques such as plasma spraying. To date the knowledge of the bonding processes and the structure of the particles within thermal spray coatings is very subjective. The aim of this research is to improve our understanding of these materials through the use of IBA techniques in conjunction with other materials analysis techniques. Samples were prepared by spraying a widely used commercial NiCr powder onto substrates using a HVAF (high velocity air fuel) thermal spraying technique. Detailed analysis of the composition and structure of the power particles revealed two distinct types of particles. The majority was NiCr particles with a significant minority of particles composing of SiO 2/ CrO 3. When the particles were investigated both as raw powder and in the sprayed coating, it was surprising to find that the composition of the coating meterial remained unchanged during the coating process despite the high velocity application.

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