EFFECT OF PLASMA SPRAY NANO COMPOSITE COATING ON … · 2020. 8. 27. · N PPM 50 100 1.1 Coating...
Transcript of EFFECT OF PLASMA SPRAY NANO COMPOSITE COATING ON … · 2020. 8. 27. · N PPM 50 100 1.1 Coating...
International Journal of Engineering Technology, Management and Applied Sciences
www.ijetmas.com September 2014, Volume 2 Issue 4, ISSN 2349-4476
1 P.Vijayanand, Amitesh kumar, K.R.Vijayakumar , K RameshBabu
EFFECT OF PLASMA SPRAY
NANO COMPOSITE COATING ON MILD STEEL
P.Vijayanand1
Amitesh kumar2
K.R.Vijaya kumar3
Research scholar, Ranchi University, Assistant. Professor, NIFFT Professor, Dr.MGR.ERIU
Md.Nazir Hussain
4 P.Kumaran
5 K RameshBabu
6
Associate Professor, CIT, Associate Professor, Saveetha University Professor & HOD, ADCET, S.U.
ABSTRACT
The development of nanotechnology enables to reinforce or improve the metallurgical and mechanical properties of
the deposited layer. In this work, coating of mild steel using the nano Composite material of Al2O3 with 13%TiO2 &
0.2%Graphene will be carried out and metallurgical and morphological changes in the resulting coating will be
examined. The coating is produced by different processes, which are the Plasma spray coating, wire arc, HVOF etc.
In this review is based on characterization of plasma sprayed nano structured coatings on Mild steel. By adding nano
particles, the properties are investigated like hardness, wear resistance etc. Consequently, investigation of the
resulting coating properties becomes essential. The objective of the present study is to investigate the metallurgical
and morphological changes in the coatings produced by plasma spraying process using nano powders.
Keywords
Al2O3:13% TiO2coating, Graphene microstructure, plasma spraying process.
1. INTRODUCTION
A coating is produced by a process in which molten or softened particles are applied by impact
onto a substrate. A common feature of all thermal spray coatings is their lenticular or lamellar
grain structure resulting from the rapid solidification of small globules, flattened from striking a
cold surface at high velocities. Figure 1 shows schematic sketch of thermal spray process.
Thermal Spraying is a technique of coating manufacturing implementing a wide variety of
processes and materials. Atmospheric plasma spraying (APS) is one of these processes based on
the creation of a plasma jet to melt a feedstock powder. Powder particles are injected with the aid
of a carrier gas; they gain their velocity and temperature by thermal and momentum transfers
International Journal of Engineering Technology, Management and Applied Sciences
www.ijetmas.com September 2014, Volume 2 Issue 4, ISSN 2349-4476
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from the plasma jet. At the surface of the substrate, particles flatten and solidify rapidly forming
a stack of lamellae. Micro-cracks appear also in the microstructure as a consequence of stress
Accommodation due to the high spray temperature and a large difference in thermal dilation
coefficients between the substrate and coating. This is mainly the case for ceramic coatings
deposited on metallic substrates (3).
Fig 1: Thermal spray coating process
Thermal spray techniques such as plasma spray, molten and accelerated toward a substrate where
it impacts creating a coating are widely used in industry (4)
Plasma sprayed ceramic coatings, for their higher strength-to-weight ratio and superior wear-
resistant properties, are preferred in most tribological applications. The suitability of a ceramic
coating on metal substrates depends on (a) the adherence strength at coating–substrate interface
and (b) stability at operating conditions. Critical components in high-tech industries operate
under extremely hostile conditions of temperature, gas flow, heat flux, and corrosive media,
which severely limit their service life. This problem can be overcome by using composite
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www.ijetmas.com September 2014, Volume 2 Issue 4, ISSN 2349-4476
3 P.Vijayanand, Amitesh kumar, K.R.Vijayakumar , K RameshBabu
Structures consisting of the core material with a suitable surface coating. Plasma spray
technology, the process of preparing overlay coating on any surface, is one of the most widely
used techniques to prepare such composite structural parts with improved properties and
increased life span. Composite coatings are defined as the deposits produced by thermal spraying
containing at least two distinctive, intentionally present phases apart from porosity.
In plasma arc spray, an electric arc is used to indirectly melt the coating material by creating a
plasma flame. The plasma flame is achieved by ionizing a plasma gas mixture such as argon,
nitrogen, helium or hydrogen. The inert gas temperature must be increased to elevated levels, to
reach the ionization state of the gas. As a result, an electric arc, this has a temperature in
excess of 5,000oK, is used and maintained along with the constant flow of the inert gas to
maintain the plasma flame. Using plasma as a heat source, it is possible to thermally spray a
wide range of materials that is not limited to polymers and metals only, but also extended to high
melting temperature materials such as ceramics. The coating material is generally in the powder
form. Commercial agglomerated nano powders are now avail- able. However, the process must
be carefully controlled in order to keep the initial nanostructure in the final coating (6).
Fig 2: Plasma spray process
International Journal of Engineering Technology, Management and Applied Sciences
www.ijetmas.com September 2014, Volume 2 Issue 4, ISSN 2349-4476
4 P.Vijayanand, Amitesh kumar, K.R.Vijayakumar , K RameshBabu
The Plasma Spray Process is basically the spraying of molten or heat softened material onto a
surface to provide a coating. Material in the form of powder is injected into a very high
temperature plasma flame, where it is rapidly heated and accelerated to a high velocity. The hot
material impacts on the substrate surface and rapidly cools forming a coating.
Plasma spraying of nano sized powder is a well-established process in this decade (2).Below
composition of HR Plate of IS2062 can be used as Substrate.
Table 1: Chemical Composition & Mechanical Composition for IS2062 HR Plate
Chemical
Composition percentage Range
Carbon 0.14 0.23Max
Manganese 0.81 1.5Max
Sulphur 0.021 0.045Max
Phosphorous 0.025 0.045Max
Aluminum 0.027 0.02Min
Silicon 0.109 0.4Max
C equivalent 0.275 0.42Max
YS 355 255Min
UTS 458 410Min
Elongation 34 23Min
Bend ok
N PPM 50 100
1.1 Coating Materials Preparation:
In the plasma spraying process, particles of Al2O3:13%TiO2 and graphene powder are injected
into plasma jet and are rapidly melted and accelerated to produce stream of molten particles that
are spray onto the substrate Mild steel plate(40mmx80mmx4mm).
And using Graphene nano sized powders feedstock to generate nano structured coatings presents
new challenges as well as new opportunities. The typical spraying parameters for
Al2O3:13%TiO2also carried out of similar substrate used. Graphene powder of 0.2% added in the
Al2O3:13%TiO2. The thickness of the Graphene powder is 5nm. The purity of Carbon in the
graphene is 99%.
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1.2 Plasma spraying parameters:
This is a typical plasma spray system operating in the non-transferred mode. The major
components of this set-up include the plasma torch, power supply, power feeder, plasma gas
supply, control console, cooling water, and the spray booth. Prior to spraying, the substrates are
grit blasted by compressed air at a pressure of 3 kgf/cm2.Acurrent regulated DC power supply is
used. A four stage closed loop centrifugal pump at a pressure of 10 kgf/cm2 supplies cooling
water for the system.
The primary plasma gas (argon) and the secondary gas (hydrogen) are taken from normal
cylinders at an outlet pressure of 4kgf/cm2. The plasma torch input power is varied from 11 to
21kW by controlling the gas flow rate, plasma arc current, and the arc voltage. The powder feed
rate is kept constant at about 11.5 g/min by a turntable type volumetric powder feeder. Operating
parameters used during the spraying are given in Table 2
Table 2: Operating parameters used during the plasma Spraying process.
Parameters used
in the SutzlerMetco USA
Range
Spray Torch 9MB
Operating Power 11-21KW
Current 500A
Voltage 65-70V
Plasma gas (Ar) flow rate 100psi
Secondary gas (H2) flow rate 15psi
Powder feed rate 11.5gm/min
Spray Distance 13”
Pre-work Grit Blasting
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2. RESULT & DISCUSSION:
2.1 Hardness of the coatings: Vickers micro hardness measurements were performed under a 0.5Kg load
for 15s on the cross-sections of the coatings. A total of 6 micro hardness measurements were carried out for each
coating. The mean micro hardness of both coating is about 3200& 1400. The observed hardness difference is
believed to result partially from different coating due to grapheme powder affects the coating hardness.
Fig 3: Vickers Micro hardness Machine Table 3: Vickers Micro hardness
2.2 Adhesive test: Tap Test method as per ASTM D3359.
On metal substrates, a more formal version of the knife test is the tape test. Pressure sensitive
tape is applied and removed over cuts made in the coating. There are two variants of this test; the
X-cut tape test and the cross hatch tape test.
The X-cut tape test is primarily intended for use at job sites. Using a sharp razor blade, scalpel,
knife or other cutting device, two cuts are made into the coating with a 30o – 45
o angle between
legs and down to the substrate which intersects to form an “X”. A steel or other hard metal
S.
no
Al2O3+TiO2
H.V @ 0.5 Kg
Load :Dwell:
10s
Al2O3+TiO2+Graphene 0.2%
H.V @ 0.5 Kg Load :Dwell: 10s
1
3197.0
1391.0
2
210.0
1395.0
3
3194.0
1411.0
4
3220.0
1413.0
5
3194.0
1395.0
6
3220.0
14130
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7 P.Vijayanand, Amitesh kumar, K.R.Vijayakumar , K RameshBabu
Straight edge is used to ensure straight cuts. Tape is placed on the center of the intersection of
the cuts and then removed rapidly. The X-cut area is then inspected for removal of coating from
the substrate or previous coating and rated.
The cross hatch tape test is primarily intended for use in the laboratory on coatings less than 5
miles (125 microns) thick. It uses a cross-hatch pattern rather than the X pattern. A cutting guide
or a special cross-hatch cutter with multiple preset blades is needed to make sure the incisions
are properly spaced and parallel. After the tape has been applied and pulled off, the cut area is
then inspected and rated.
Fig 4.1-Al2O3:13%TiO2 (before) Fig 5.1 -Al2O3:13%TiO2:0.2%Graphene (before)
Fig 4.2 -Al2O3:13%TiO2 (After) Fig 5.2 - Al2O3:13%TiO2: 0.2%Graphene (After)
International Journal of Engineering Technology, Management and Applied Sciences
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8 P.Vijayanand, Amitesh kumar, K.R.Vijayakumar , K RameshBabu
Fig6-Pasting tape on Substrate Fig 7- Peel-Off tape from Substrate
Sharp 450 hatched lines made at equidistance with the help of sharp H.S.S. tool bit on the
surfaces of Al2O3 : 13%TiO2(Fig 4.1 &4.2) & Al2O3 : 13%TiO2:0.2%Graphene( Fig 5.1, 5.2)The
image shows the hatched surface after the peel off test is conducted(Fig7). The complete squares
are intact and no coating has been removed from the coated surface of the Al2O3:13%TiO2 &
Al2O3:13%TiO2: 0.2%Graphene.Both the coated has good adhesive strength.
A rough surface provides a good coating adhesion. A rough surface provides enough room for
anchorage of the splats facilitating bonding through mechanical interlocking (3).
2.3 Coating Characterization:
EDX analysis was performed to determine the atomic composition of the different phases found
in the coatings of Al2O3:13%TiO2 & Al2O3:13%TiO2: 0.2% Graphene. Coatings are confirmed to
be formed by melted matrix particles of TiO2& Graphene.
International Journal of Engineering Technology, Management and Applied Sciences
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9 P.Vijayanand, Amitesh kumar, K.R.Vijayakumar , K RameshBabu
Fig 8 EDX Analysis of nano structured Al2O3: 13%TiO2
Fig 9 EDX Analysis of Nano structured Al2O3 : 13%TiO2: 0.2%Graphene
2.4 Coating Micro Structure:
The Cross section of the coatings was studied with FESEM. The coatings Al2O3:13%TiO2
relatively denser compared to their Al2O3:TiO2:0.2%Graphene due to oxidation effect. Oxidation
of metals and alloys took place when they are heated to elevated temperatures in air or highly
oxidizing environment (14).
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10 P.Vijayanand, Amitesh kumar, K.R.Vijayakumar , K RameshBabu
Fig 10. SEM analysis of Al2O3 :13%TiO2 coated surface of SubstrateAl2O3 : 13%TiO2: 0.2% Graphene
Fig 11 .SEM analysis of Al2O3:13%TiO2 coated surface of Substrate
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11 P.Vijayanand, Amitesh kumar, K.R.Vijayakumar , K RameshBabu
3. RESULTS:
I. Effects of Plasma sprayed coatings have different composition with different parameters
analyzed.
II. Determination of mechanical properties like hardness, Adhesive in the coated mild steel
plates.
III. Addition of Graphene powder in the Al2O3:13%TiO2 have shown lesser Micro hardness &
can be used in the application of bending work.
IV. If uniformly deposited, shows improved properties like more surface adhesive &Micro
hardness.
V. Mild steel substrate of Hot rolled materials (IS2062) have analyzed by adhesive, hardness
test.
VI. If graphene content increases, electrical conductivity & Thermal conductivity also increases.
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