Influence of Spraying Process Parameters on the Characteristics of Steel Coatings Produced by Arc Spraying Method

IF 2.9 3区 材料科学 Q2 MATERIALS SCIENCE, COATINGS & FILMS
Coatings Pub Date : 2024-09-05 DOI:10.3390/coatings14091145
Bauyrzhan Rakhadilov, Nurtoleu Magazov, Dauir Kakimzhanov, Akbota Apsezhanova, Yermakhan Molbossynov, Aidar Kengesbekov
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Abstract

Arc spraying is one of the most effective and cost-efficient thermal spraying technologies for creating high-quality protective coatings. This paper examines the influence of arc spraying process parameters on the properties of steel coatings. The parameters varied in this study included gas pressure, wire feed rate, and the distance from the spray gun to the substrate (standoff distance). Experimental evaluations focused on surface roughness, thickness, porosity, structure, and hardness of the coatings. The techniques used for these evaluations included profilometry for roughness measurement, scanning electron microscopy (SEM) for structural analysis, Vickers hardness testing, and optical microscopy. The results demonstrate a significant influence of arc spraying parameters on the characteristics of the resulting coatings. The analysis revealed that the coatings produced under different modes exhibit a layered structure and vary in thickness. A detailed examination of the coating structure identified defects such as unmelted particles, voids, and delamination in the interface zone. The study of coating thickness and porosity showed that increasing the wire feed rate and decreasing the standoff distance leads to the formation of thicker and denser coatings. Specifically, increasing the wire feed rate from 2 to 12 cm/s resulted in a decrease in porosity from 12.59% to 4.33% and an increase in coating thickness to 699 μm. The surface analysis highlighted the importance of a comprehensive approach to selecting the optimal roughness. While increasing the wire feed rate up to 12 cm/s can increase the Ra roughness parameter, gas pressure also significantly influences this parameter, reducing roughness from Ra = 18.63 μm at 6 MPa to Ra = 15.95 μm at 8 MPa. Additionally, it was found that varying the arc spraying parameters affects the hardness of the coatings, with all modes resulting in hardness values higher than that of the substrate. Therefore, optimizing these parameters enables the achievement of the best combination of mechanical and structural properties in the coatings. These findings can be valuable for further improvement of arc spraying technologies and the expansion of their application across various industries.
喷涂工艺参数对电弧喷涂法生产的钢涂层特性的影响
电弧喷涂是制造高质量保护涂层的最有效和最具成本效益的热喷涂技术之一。本文研究了电弧喷涂工艺参数对钢材涂层性能的影响。研究中变化的参数包括气体压力、送丝速度和喷枪到基材的距离(间距)。实验评估的重点是涂层的表面粗糙度、厚度、孔隙率、结构和硬度。这些评估采用的技术包括粗糙度测量的轮廓仪、结构分析的扫描电子显微镜(SEM)、维氏硬度测试和光学显微镜。结果表明,电弧喷涂参数对所产生涂层的特性有很大影响。分析表明,在不同模式下产生的涂层呈现分层结构,厚度也各不相同。对涂层结构的详细检查发现了一些缺陷,如未熔化颗粒、空隙和界面区的分层。对涂层厚度和孔隙率的研究表明,提高送丝速率和减小间距可形成更厚、更致密的涂层。具体来说,将送丝速度从 2 cm/s 提高到 12 cm/s,孔隙率从 12.59% 降至 4.33%,涂层厚度增至 699 μm。表面分析强调了综合选择最佳粗糙度的重要性。虽然将金属丝进给速度提高到 12 cm/s 可以增加 Ra 粗糙度参数,但气体压力也会对该参数产生重大影响,使粗糙度从 6 MPa 时的 Ra = 18.63 μm 降低到 8 MPa 时的 Ra = 15.95 μm。此外,研究还发现,改变电弧喷涂参数会影响涂层的硬度,所有模式下的硬度值都高于基底的硬度值。因此,优化这些参数可使涂层的机械性能和结构性能达到最佳组合。这些发现对进一步改进电弧喷涂技术和扩大其在各行各业的应用具有重要价值。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
Coatings
Coatings Materials Science-Surfaces, Coatings and Films
CiteScore
5.00
自引率
11.80%
发文量
1657
审稿时长
1.4 months
期刊介绍: Coatings is an international, peer-reviewed open access journal of coatings and surface engineering. It publishes reviews, research articles, communications and technical notes. Our aim is to encourage scientists to publish their experimental and theoretical results in as much detail as possible. There is no restriction on the length of the papers. Full experimental and/or methodical details must be provided. There are, in addition, unique features of this journal: * manuscripts regarding research proposals and research ideas will be particularly welcomed * electronic files or software regarding the full details of the calculation and experimental procedure - if unable to be published in a normal way - can be deposited as supplementary material
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