Effect of NiFe2O4 Phase and tribological properties on Vacuum plasma spray Cr3C2+25NiCr coating ER 2205 - 66Co26Cr5WC filler high-strength alloy plate fabricated by wire arc additive manufacturing process

IF 6.3 3区工程技术 Q1 ENGINEERING, CHEMICAL

Journal of the Taiwan Institute of Chemical Engineers Pub Date : 2025-09-30 DOI:10.1016/j.jtice.2025.106418

M. Karthikeyan, R. Selvabharathi

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引用次数: 0

Abstract

Background

In the present research effort, single-layer deposition was used to fabricate high-strength alloy plates for wire arc additive manufacturing (WAAM) procedures using 2205 (FeCr-WAAM), 66Co26Cr5WC (CoCr-WAAM), and Fe-interface metallic (Fe-IM). The study aimed to improve the mechanical characteristics and surface morphology of high-strength alloy plate samples by comparing WAAM samples with those coated using plasma spray, focusing on microstructure, hardness, porosity faults, and wear resistance.

Methods

Microstructural analyses were carried out using SEM and EBSD techniques. For 2205 filler wire samples, FeCr₂O₄ multiferroic spinel, γ’-austenite crystal (AC), and CrCo biomaterial phases were observed. The 66Co26Cr5WC filler showed Co-rich solid structures (CSS), martensitic ferrite transformation (MFT), and CrO₃ crystal structures under varying heat inputs. EBSD revealed that Fe-IM samples coated with plasma spray exhibited NiFe₂O₄ cubic ferromagnetic oxide, MnCr₂O₄, and MnO₄ lattice structures, while uncoated Fe-IM samples showed NiFe₂O₄, Fe₃O₄, and CoFe₂O₄ phases. Bulk texture analysis indicated that interface metallic coated surfaces (Fe-IMC₁<200>, Fe-IMC₂<022>, Fe-IMC₃<111>, and Fe-IMC₄<311>) contained more nickel and cobalt compared to outer surfaces. Inner surface layers of Fe-IM₁<001>, Fe-IM₂<111>, and Fe-IM₃<110> showed multiferroic CoFe structure and α-austenite crystal structure. Wear resistance and corrosion studies were performed on WAAM, WAAM-IM, and WAAM-C sample surfaces.

Significant findings

Compared to the 2205 filler wire samples, the Fe-IM coated samples exhibited a 14 % higher hardness value. The NiFe₂O₄ structure was found to provide protection to both inner and outer surface layers of the samples. These findings suggest that interface metallic coating and plasma spray treatment significantly enhance the mechanical and surface characteristics of WAAM-fabricated high-strength alloy components.

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NiFe2O4相及摩擦学性能对真空等离子喷涂Cr3C2+25NiCr涂层ER 2205 - 66Co26Cr5WC填料电弧增材制造高强合金板的影响

本研究以2205 （FeCr-WAAM）、66Co26Cr5WC （CoCr-WAAM）和Fe-IM为材料，采用单层沉积法制备了用于电弧增材制造（WAAM）的高强度合金板。本研究旨在通过比较等离子喷涂和WAAM涂层的高强度合金板样品的力学特性和表面形貌，重点研究显微组织、硬度、孔隙缺陷和耐磨性。方法采用扫描电镜（SEM）和EBSD技术进行显微结构分析。在2205填充丝样品中，观察到FeCr₂O₄多铁尖晶石、γ′-奥氏体晶体（AC）和CrCo生物材料相。66Co26Cr5WC填料在不同的热输入下表现出富co固体结构（CSS）、马氏体铁素体相变（MFT）和CrO₃晶体结构。EBSD表明，等离子喷涂的Fe- im样品具有NiFe₂O₄立方铁磁氧化物、MnCr₂O₄和MnO₄晶格结构，而未涂层的Fe- im样品具有NiFe₂O₄、Fe₃O₄和CoFe₂O₄相。体织构分析表明，界面金属涂层表面（Fe-IMC1<200>；、Fe-IMC2<022>；、Fe-IMC3<111>；和Fe-IMC4<；311>）比表面含有更多的镍和钴。Fe-IM1<001>；、Fe-IM2<111>；、Fe-IM3<110>；的内表面层表现为多铁CoFe结构和α-奥氏体晶体结构。对WAAM、WAAM- im和WAAM- c样品表面进行了耐磨性和腐蚀研究。与2205填充丝样品相比，Fe-IM涂层样品的硬度值提高了14%。发现NiFe₂O₄结构为样品的内层和外表层提供保护。这些结果表明，界面金属涂层和等离子喷涂处理显著提高了waam制备的高强度合金部件的力学性能和表面特性。

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来源期刊

Journal of the Taiwan Institute of Chemical Engineers 工程技术-工程：化工

CiteScore

9.10

自引率

14.00%

发文量

362

审稿时长

35 days

期刊介绍： Journal of the Taiwan Institute of Chemical Engineers (formerly known as Journal of the Chinese Institute of Chemical Engineers) publishes original works, from fundamental principles to practical applications, in the broad field of chemical engineering with special focus on three aspects: Chemical and Biomolecular Science and Technology, Energy and Environmental Science and Technology, and Materials Science and Technology. Authors should choose for their manuscript an appropriate aspect section and a few related classifications when submitting to the journal online.