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8 INTERNATIONAL CONFERENCE ADVANCED MANUFACTURING OPERATIONS

Comparative Assessment Of Mechanical Properties Of Thermal Sprayed Coatings

P.Dinkov,InstituteofMetalScience,BulgarianAcademyofSciences,67,Shipchenskyprohod-Str.,BG-1574 Sofia;e-mail:p.dinkov@ims.bas.bg

Abstract: The article presents investigations of the mechanical properties of thermal sprayed coatings with application as thermal barrier -and wear-resistance shields. The applied 7 different thermal spraying powders were based on: NiCrBSi, NiCr-WC, Al2O3/TiO2 , Cr3C2-NiCr , ZrO2/Y2O3 , WC-Co and NiMoAl. As spraying methods were chosen the flame spraying with subsequent sintering and the atmospheric plasma spraying. The produced composite coatings have been subject to specific tests to get knowledge about the complex loadability and to mark tendencies to their application for thermomechanical protection. The tests included investigations of the adhesion tensile strength, the bending behaviour, the wear resistance and rotating bar bending experiments. To interprete the results received more meaningful, there were performed metallographical investigations and pilot-tests for thermal fatigue resistance. The testing programme was completed by accompanying investigations of the micro-hardness and the surface roughness of the coating layer composites. The experiments have been subsequently assessed and discussed. Key words: thermal spraying, composite coatings, mechanical properties, ceramic spraying powders

1. Introduction Inwideareasofthemechanical,chemicalandmetallurgicalplantengineeringoccursavarietyofwearand corrosionproblems.Significantfinancialcostsarearisingduetorepairingmeasuresandplantoutages.Agreat part of these problems can be prevented applying diverse coatings on high loaded construction elements in thewaythatevenlongerstandingtimethannewpartsdohavearetobeachieved.Technologiesliketheflame sprayingwiththermalpost-densification(TS+TN)andtheatmosphericplasmaspraying(APS)arespraying (orsemi-welding)methods,whichareusedwhereaneconomicalcoatingprotectionofbigconstructionpartsis requiredunderhighratesofdeposition.Thesoproducedcoatings(andcoatingsystems)cangivenewproperties totheconstructionparts[1],[2]. 2. Experimental conditions ThematerialsdescriptionisgivenintheTable1.Thefirsttwosprayingpowdersweredepositedonthesubstrate surfacebymeansofflamesprayingwithadditionalthermalpost-densification(subsequentlysintered).The restpowdershavebeenprocessedbyAPS.TheNiMoAl-powder(itemNr.7)wasusedadditionallyasbonding intermediatelayerintheceramicgradesitems3,4and5. ThebasematerialswerenonalloyqualitysteelsSt37-2(S235JREN10025)andC15(EN10277-2).Allof thesampleshavebeendriedoutandpreheatedforatleast24hoursinadryingchamberat100120C.Directly before applying of spraying the surfaces of the substrate samples were sandblasted with corundum of grain size [-500+1200m].ThusitwasensuredthatthesamplessurfacesbecameanequalroughnessofRz6474. 3. Results 3.1 Metallography OnFigure1isshownacoatingwhichhasadenseandcoherentstrucuture,typicalfortheflamespraying
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Comparative Assessment Of Mechanical Properties Of Thermal Sprayed Coatings

Table 1 Spraying materials Chemical composition Grain size [weight- %] [m] 1 NiCrBSi C0,75;B3,5;Si4;Cr16;Fe3;Cu -125+45 2,5;Mo2,5;Ni67,75 2 NiCr-WC EutalloyRW12112, C0,45;Ni47;Cr11,5;Fe3,5;Synerg. No Castolin elementsca.2,5;WCRest(34%) reference 3 Al2O3/ Amperit742.069(HCST Al2O3 96min.;SiO20,6max.;TiO23,5max.; -40+10 TiO2-97/3 HermannStarck) FeO0,05max. 4 Cr3C2Amperit584.1(HCST) Cr:6771;C:9,510,3;Ni:1822;O:0,8 -45+22,5 NiCr-75/20/5 max. 5 ZrO2/Y2O3-93/7 Amperit827.1(HCST) Y2O3:6-8;HfO2:2,5max.SiO2 :1max.;TiO2: 0,4 -45+22,5 max.;Al2O3 :0,2max.FeO:0,2max.;ZrO2 Rest 6 WC-Co Amperit515.400(HCST) Co:11-13;C:3,64,2;Fe:2max.;WRest acc.AMS 88/12 7879 7 NiMoAl* Amperit271.2(HCST) Ni:85-90;Mo:4-6;Al:4-6;Fe:1max.;Mn:1 -90+45 90/5/5 max.;Si:1max.;C:0,5max. *)Annotation:ThepowderNr.7(NiMoAl)wasusedinthecoatingqualities3,4,and5asadhesionbondinglayer [0.050.10mm]. withsubsequentlythermaldensificationThehardtungstencarbideparticles(microhardnessHV0,1=1761)are distributedintheNiCrmatrix(HV0,1=785)informofclasters.Biggerporesincomparisonwiththatofthe system1(NiCrBSi)areconspicuous.Therecanbenoticedsimilardefectslikeinthetransitionzonecoatingsubstrateofthesystem1. Nr. Description Description by manufacturer 11.16.3GTV

Figure 1FlamesprayedEutalloyRW12112, Castolin(NiCr-WC);withoutbondcoat;x200

Figure 2Plasmasprayed(APS-method)Amperit827.1 (ZrO2/Y2O3-93/7);withbondcoatNiMoAl;x200

ThestructureonFigure2isrepresentativeforAPSandlookssimilartothatofthecoatingsystem3.Itisfine grainedandstronginfiltratedbypores.Therearenoevidentporeconcentrationsdirectlyatthetransitionzonebond coattopcoat.Theexistencehoweverofseparateporesinthisareacanbedeemedasareason(alongwiththe residualstressstatesubjectofadditionalinvestigations)forthefractureinitiationduringthesubsequentadhesion tensilestrengthtests. 3.2 Bending tests TheFigures3and4areexamplesshowingtheachievedgradeofformability.Thebendinganglehasbeen measuredafterloadremoval.TheresultsaresumarizedinTable2.ItcanbeobservedthattheAPSsandvich structures(bondcoat+topcoat)exhibitsignificantlybiggerbendinganglestillthefirstcracksinitiationsoccure.
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Therearetworeasonsforthem: 1)Thecoatingcompoundsofgrades3,4and5arethinnerthantherest.Thecoatingthicknessvariesbetween0.34 and0.47,whiletherestcoatingsNr.1,2,6and7weredepositedupto0.7mm. 2)Thesandvichstructure(bondcoat+topcoat)oftheAPScoatingsenablestheestablishmentofasuitableresidual stressstateinthemanner,thatthecompressionpreliminarystressesofthecoatingcompoundscanreceivehigher tensileloadingduringthebendingdeformationprocess.

Figure 3Bentsamples(150x20x5mm):coating system2(NiCr-WC). Table 2 Bending tests Coating Nr 1 2 3 4 5 6 7 Bending angle [grade] 8 6 20 22 27 7 8

system3(Al2O3/TiO2-97/3);Down:coatingsystem5(ZrO2/ Y2O3-93/7);

Figure 4Bentsamples(150x20x5mm):Up:coating

Series A Coating thickness [ mm ] 0.55 0.46 0.36 0.43 0.34 0.55 0,70

Bending angle [grade] 1.5 12 23 9 18 4 12,5

Series B Coating thickness [ mm ] 0.60 0.38 0.41 0.47 0.47 0.48 0,54

3.3 Bonding strength (Adhesion tensile strength) Themeasuredhighadhesionstrengthvaluesoftheflamesprayedspecimensofthesystems1and2giveno informationaboutthecoatingadhesion,butaboutthestrengthoftheadhesiveassuch,becausethefractureoccurred alwaysintheadhesive.Thebondingstrengthofsimilarflamesprayedcoatingswithsubsequentdensificationis formedpredominantlybyintensivelocalmetallurgicalinterchangesandlocalweld-fusings. Table 3 Adhesion tensile strength of the investigated thermal sprayed coatings Nr 1 2 3 4 5 6 7 NiCrBSi67,5/16/3,5/4 NiCr-WC;(47/11,5/34) Al2O3/TiO2-97/3 Cr3C2-NiCr-75/20/5 ZrO2/Y2O3-93/7 WC-Co 88/12 NiMoAl 90/5/5 Material Adhesion tensile strength, RH, [N/mm2] 67 64 37 49 27 58 60

InTable3areshowncomparativelytheevaluatedbondingstrengthsoftheAPS-andflamesprayedcoating compounds.TheWC/Co88/12sprayingmaterialbelongstotheseriesAmperit-515ofthecompanyH.C.Starck.It isamoltentungstencarbidecobaltpowder,whichparticlescontainasmeanparttungstencarbide,besidescobalt andsmallerpartsofcomplexCo-W-C-compositions.Thiscontentdeterminesthefinecarbidelayermorphology,

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Comparative Assessment Of Mechanical Properties Of Thermal Sprayed Coatings

whichischaracterizedbyfineporesthroughouttheentirestructure.ThehighvaluesofWC/Co88/12and NiMoAl90/5/5confirmsomeresultsfromforerunnerworks[3]andfromothersources[4],[5].Theirwearrates inaccompanyingtestswerealsothelowest.Aperfectthermalsprayedbondingbetweensubstrateandcoatingwas observed.

Figure 5 Cross-view of the surfaces of one coated test specimen and the counter solid after their breaking. Coating: Cr3C2-NiCr-75/20/5 with NiMoAl as intermediate bonding layer break in the transition zone between bond coat and top coat (koaesive fracture)
The ZrO2-coatingsareexpressingthetendencytorelativelylowadhesionstrengthvalues(ca.27N/mm2)andthefractureappears upto90%attheinterfacebetweenbond coat(NiMoAl)andtopcoat(ZrO2/Y2O3). Attheduplexcoatings(systems3,4and5)thefractureappearspredominantlyinthetransitionzonetopcoatbondcoat(Figure5). TheNiMoAlbondcoatpowder(Amperit271.2)isaspherical,alloyedpowder,whosehighNi-contentof85-90weight% (s.Table1)securesastrongbondwiththeNiCr-matrixofthetop-coatinthecaseofsystem4(Cr3C2-NiCr). The coherent morphologyofthecoatingcompoundexplainsthedifferentfracturecrosssectionsintheadhesiontensiletests.Thesocalled cohesivefracturecouldbeobservedespecially(Figure5).

3.4 Rotating bar fatigue tests TheresultsaregiveninFigures6and7usingtheachievedstressnumbercurves(SN-curves).Fracturesand destroying of specimens are visualized by arrow shown in down direction while in case of intact specimen the arrow isinupperdirection. After comparison between the zones of the fatigue endurance strength of the coated specimens and of the uncoated basematerialS235-JR(Figure7thickline)itgetsobviousthatthematerialcompoundsfittedwithcoatingsZrO2/ Y2O3,Al2O3/TiO2,WC-NiCrandWC-Coexhibitahigherpositionedfatigueendurancelimitzones. InterestingresultswereobtainedwiththespecimensfittedwithCr3C2-NiCr(andNiMoAlasbondcoat).Inspite of the fact that the fatigue endurance limit was in much lower position on the diagram than the endurance limit of thebasemetal,thetransitionfromthefatiguestrengthforfinitelifeorthecreeprupturestrength(decreasingcurve zone)tothefatigueendurancelimitzone(horizontalcurvezone)occursearlier(slightlybefore105cycles). At the rotating symmetric specimens with coating compounds completely of NiCrBSi or with NiMoAl the horizontalareaofthecurvesbeginsearliertoo,butwithvaluesremarkablylowerthanthepuresteelsubstrate S235-JRdoes(Figure7).Thefatiguestrengthforfinitelifeorthecreeprupturestrengthareas(decreasingcurve zones)ofthesecoatedspecimensaresituatedclosedtoeachother.ThespecimenscoatedwithWC-Coexhibita decreasingcurvezone,whichismovedtothehighestcyclenumbers(totherightdirectionofthediagram). Apartfromthetimelymovedtransitionzonesbetweenthefatiguestrengthforfinitelife(decreasingcurvezone)and thefatigueendurancelimitzone(horizontalcurvezone),thespecimenswithZrO2/Y2O3(System5),Al2O3(System 3)andWC-NiCr(System2Eutalloy)exhibitanincreasingofthefatiguestrengthincomparisontothenoncoated S235-JRspecimens.

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3.5 Thermal fatigue resistance tests The test results of the thermal fatigue resistance arepresentedinFigure8,Tables4and5.Inthe casesofthecoatingqualities1,2,3and5there couldbefindneitherthermalinducedcracks, norsomechangesofcolour.Howeveratthe coatingsystem4(Cr3C2 NiCr and NiMoAl asbondcoat)thefirstchangesofcolour occurredafterabout20cycles.Butafteroptical observation with stereo lens there were not any cracksnoticed.Thesameresultcameoutat theNiMoAlcoatings(quality7).Thecracks however,occuredhereafterabout120 cycles (Table4). Figure 6SN-curves:rotatingbarfatiguetestsofthermalsprayed specimens WC-Co88/12coatings(coatingsystem Nr.6): All the tested WC-Co coatings failed after the 40thcyclus.Mostlyabout50%ofthecoating spalledcomplete.Howeverthecoatingasinits intimatestructureremainedintactandsolid. Inordertodefinetheoperationzoneofthis coating system regarding its thermal fatigue resistance,testswereconductedatlower temperatureasfollows(s.Table5):coating thickness:0.6mm;tacttime:15seconds; maximum heating temperature Theat=440C; cooling temperature Tcool=235C. Underthequotedconditionswerereached cyclenumbersupto630withoutanyfailure. CommentstoTable4: Figure 7SN-curves:comparisonofrotatingbarfatiguetestson uncoatedandcoatedsteelSt37-2(S235JRDIN:EN10025)with ForNr.4:Afterthe20th cycle occured yellowNiMoAl90/5/5(Amperit271.2(HCST)). browncolourchanges;Afterthe40th cycle total blue-purple colour changes ForNr.6:Afterthe15th cycle green-blue colourchanges;Afterthe40th cycle spalling ForNr.7:Firstcracksandlocalyellowcolour changes after the 120thcycle; For better illustration the results are given comparedinTable6.Thethermalfatigue resistanceandthewearresistanceacc.[6]of the coating compounds are presented with a qualitativeassessment.

Figure 8Thermalfatigueresistancetests:T2=620[C];T1=RT (roomtemperature);tacttime:5minutes

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Comparative Assessment Of Mechanical Properties Of Thermal Sprayed Coatings

Table 4 Testing of the thermal fatigue resistance: T2 = 620 [C]; T1 = RT (room temperature); tact time: 5 minutes Coating system NiCrBSi NiCr-WC Al2O3/TiO2-97/3 Cr3C2-NiCr-75/20/5 ZrO2/Y2O3-93/7 WC-Co 88/12 NiMoAl* 90/5/5 Coating thickness [mm] 0.6 0.7 0.1+0.5 0.1+0.2 0.1+0.2 0.6 0.6 Temperature difference: T [C] 55 65 50 55 90 60 -

Table 5 Testing of the thermal fatigue resistance (Maximum heating temperature Theat = 440C; Cooling temperature Tcool = 235C) Nr 4 6 Coating System Cr3C2-NiCr WC-Co BC Bond coat [mm] 0,1 TC Top coat [mm] 0,2 0,6 Tact time [s] 15 15 Cycles number 630 630 TDS [C] 230 440 TS [C] 210 235

Table 6 Overview of test results with qualitative assessment Nr Material Manufacturer`s description Method Structure Hardness Raughness Wear (s.tab. 3) [Rz] resist. *) Thermal fatigue resistance [620C RT]**)

1 2 3 4

NiCrBSi 67,5/16/3,5/4 (-125+45m) NiCr-WC 47/11,5/34 Al2O3/ TiO2-97/3 (-40+10m) Cr3C2NiCr-75/20/5 (-45+22,5m)

11.16.3(GTV) EutalloyRW12112 (Castolin) Amperit742.069 (HCSTHermann Starck) Amperit584.1 (HCST)

FS+ TN FS+ TN APS APS Matrix Carbide BC TC BC TC APS BC TC APS

718HV0,1

24

785HV0,1 31 1761HV0,1 230HV0,05 33 1413HV0,1 276HV0,05 47 1192HV0,1 280HV0,05 39 1192HV0,1 1390HV0,1 32

ZrO2/Y2O3-93/7 Amperit827.1 (-45+22,5m) (HCST) (PYSZ) WC-Co 88/12 Grain size according to AMS 7879 NiMoAl 90/5/5 (-90+45m) Amperit515.400 (HCST) Amperit271.2 (HCST)

APS

262HV0,05 89

Legend: Wear resistance **) Thermal fatigue resistance BC:BondCoating;TC:TopCoating

146 *)

low

medium

high

Changes of colour

3.6. Wear resisting behaviour Variationsoftherunningtimeandofthecontactforcehadbeenundertakenduringthetestperforming.The volumetricwearratewasusedasacriteriaforthewearratebecauseinthiswaythevariousspecificweightof thecoatingmaterialsmightnotbeconsidered.ThefollowingdependanciesforthevolumetricwearrateVwere examinated: Asfunctionofthecontactforceatconstantrunningtimeandqualityoftheabrasivecountersolid(SiCgrade120); Asfunctionofthevariousrunningtimeatconstantcontactforceandqualityofthecountersolid(SiCgrade120). TheresultsaregivengraphicallyinFigure9(a-d).Thevolumetricwearrateasafunctionofthecontactforce isillustratedinFigure9(a).Itgetsclearthat3groupsofcoatingqualitiesinrelationtotheirwearratescanbe extracted: 1stgroup:NiCr-WCandWC-Co: Thewearratesarethelowest.AslightincreasingofthewearvolumeasfunctionofthecontactforceFncanbe noticed.Theperfectthermalsprayedbondingbetweensubstrateandcoatingwasevident. 2ndgroup:NiCrBSi,NiMoAl,Al2O3/TiO2 and Cr3C2-NiCr: Hereisremarkabletheabruptdecreasingofthewearratesofthecoatingquality4(Cr3C2-NiCr)withtheinitial increasingofthecontactforcefrom60Nto80N.Thiscanbebroughtinrelationwiththesurfaceroughnessofthe coating(s.Figure9d)andsoconcludedthattheCr3C2-NiCr-coatings(Amperit827.1)areverysusceptibleinthe initialtest-phase.SimilarbehaviourintheinitialtestphasehavetheAl2O3/TiO297/3coatings. HowevertherelativelyhighroughnessvaluesmeasuredofNiMoAl(Figure9(d)arenotleadingtohighwear rates.IncontrarytheNiMoAl-coatingshavethesamelamellarstructureastheusuallyusedinthemaintenance selffluxingNiCrBSi-basedalloys.Stillduringthelayersconsolidationinthethermalsprayingprocessoccursan optimalmechanicalclampingandwettingofthesolidifyingcoatinglayers. 3rdgroup:ZrO2/Y2O3-93/7 with NoMoAl-bond coat: Thesespecimensshowthelowestwearresistance.InFigure9baregiventheratesofthevolumetricwearasa functionofthetime.TheWC-containingcoatings(system2andsystem6)havethelowestwearrates.Inthesecond groupisanothertendencyobviousthesystems3and4(Al2O3-based and Cr3C2-based)wearidentically.Thesame isvalidforthesystems7und1(NiMoAlandNiCrBSi)inthesamegroup.Thefollowinginterpretationscanbe madebasingonFigure9d: Thesystem5(ZrO2/Y2O3)hasthehighestwearrate(about230m)underanaverageraughnessvalueofRz=39 m. Thesystem7(NiCrMoAl)occupiesthesecondplacewithawearrateofabout160m.Thevolumetricwearrate [mm3]iscomparablewiththoseofthecoatingqualities3and4(Figure9d).Theobtainedhighwearratesofsystem 7duringtheinitialtestphase(30seconds)aretoberelatedwiththehighersurfaceroughnessvalueof(Rz89m). ThenoticedfluctuationsintheresidualcoatingthicknessoftheNiCrBSi-wearspecimenswerecausedbythe unequalplaneparallelityofthecoatingsurface.Thereasonwasthequasi-molten-liquifiedstateofthecoating surfaceduringtheflamesprayingprocess(becomingvisibleasthesocalledwetappearance). In[5]wasreportedfromadhesivewearresistance(TaberAbraserTests)ofsimilarmaterials.Differentthermal sprayed coatings had been examinated in respect of their behaviour under the Stud Disc wear test conditions accordinganothersource[4].TheAPSAl2O3/TiO2-97/3 showed the highest wear resistance and let to be categorizedalongwiththeflamesprayedselffluxingNiCrBSialloys.

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a)

b)

c)

Figure 9 (a-d). Volumetric wear rates V30[mm3]asafunctionofthecontactforceFn [N],time,coatingsystems. CountersolidsurfacewithSiC-grainsize120m 4 Discussion Due to the big majority of combinations of spraying parameters and the limited literature data regarding test conditionsaswell,itisverydifficulttomakeultimatecomparativeanalysisorifsoonlywithcompromises. Usuallythematerialsrelatedaspectsofcoatingmorphologyarethoroughlydiscussedwithoutassessmentof sprayingconditionsandparametersorviceversa.HerearisestheneedofusingFEM-methodsandelectronic-optical determinationoftheopenedandclosedporosityformodelingthemorphologyofthecoatingcompounds.Atthe same time thermal and mechanical generated strain-stress states can be simulated and further compared with the test results([1],[7],[8]). Metallography: The accompanying metallographic investigations helped to give the evidence that the coating adhesion strength waslocalimpairedbyimpurities(restsofsteelandgritparticles).Acoherentporosityinthelowerareasofthe coatingstructures(howevernotacontinuousporosityreachingtothecoatingsurface)wasascertainedadditionally. Therefore a longer pure blasting stage by compressed air without grit supply is highly recommended during the substratepreparationinthegritblastingchamber.

d)

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Bending behaviour: Thecoatings3,4and5haveanoptimalthicknessandaregenerallythinnerthanthecoatingsoftherestsamples(to becomparedwiththecoatingthicknessofseriesAandBinTable2).Thethicknessesvarybetween0.34and0.47 mm,whiletherestcoatings(1,2,6and7)hadnotanybondcoatandthethicknesseswereupto0.7mm.Because ofthesandvichstructureoftheAPS-sprayedcoatingsasuitableinherentresidualstressstatehasbeenestablished, so that the compression preloaded coating compounds could receive higher tensile stress loadings during the deformationprocess. Adhesion tensile strength: The ZrO2-basedcoatingsshowedthetendencytorelativelylowadhesionstrengthvalues(ca.27N/mm2).Atthe duplexcoatings(systems3,4and5)thefractureappearspredominantlyinthetransitionzonetopcoatbondcoat. Atthesystem4(Cr3C2-NiCr)wereobserveddifferentfracturecrosssectionsbecauseofthestrongbondbetween theNi-containingbondcoatandtheNi-containingmatrixofthetopcoat(coherentmorphologies).Thesocalled cohesivefracturecouldbeenobservedespecially. Rotating fatigue strength: ThecompoundwithWC-Coexhibitsadecreasingcurvezone,whichismovedtothehighestcyclenumbers(tothe rightdirectionofthediagram). Apartfromthetimelymovedtransitionzonesbetweenthecreeprupturearea/fatiguestrengthforfinitelife (decreasingcurvezone)andthefatigueendurancelimitzone(horizontalcurvezone),thespecimenswithZrO2/ Y2O3(System5),Al2O3(System3)andWC-NiCr(System2Eutalloy)exhibitanincreasingofthefatiguestrength incomparisontothenoncoatedS235-JRspecimens.Theexplainationofsuchbehaviourcanbesearched(like preliminaryresultsofthe3-pointbendingtestshavealreadyshown[9]),inaconvenientcompressionresidual stressstate,whichisestablishedintheperipheryoftherotationsymmetricspecimens. Thermal fatigue behaviour: Inthecasesofthecoatingqualities1,2,3and5therecouldbefindneitherthermalinducedcracks,norsome changesofcolour.Howeveratthecoatingsystem4(Cr3C2NiCrandNiMoAlasbondcoat)thefirstchanges ofcolouroccurredafter20cyclesbutwithoutcracks.AlimitedthermalfatiguebehaviourshowedtheNiMoAl coatings(quality7).ItwasstatedalsothattheWC-Co-88/12-coatingshavealowresistanceagainstthermalinduced loading.Thissusceptibilitybeginsabove440C.Thelatteristruewithoutlimitationsonlyundertheconservative testconditions. Bymeansofdilatometermeasurementsthereweredeterminedlinearexpansioncoefficients of the thermal sprayedWC-Co-coatingwithvaluesof6,58(intherange:RTto300C)und7,17(RT600C).Thedifference between the measured value of of the WC-Co coating obtained and the valueforSt37-2(14.10-6K-1)as well the lack of interface bond layer between the steel substrate and the WC-Co thermally sprayed coatings are the reasons,whichcanberegardedforthefailingofthiscoatingcompound. As another reason for the failure of the WC/Co 88/12 can additionally be approached the allotrope transformation oftheCobalt-matrixat417420Cfromthehexagonal()intothecubicplanecentered()latticestructure.This transformationcancauseadistortionofthematrixassistedwithcracksinitiation.Thepartiallycoherentporosity statedinthetransitionzoneoftheinterfacecoatingsubstratecanalsobedeemedasafailurefactor([6],[9],[10]). Wear resistance: ThecoatingswithNiCr-WCandwithWC-Co(orthosecontainingtungstencarbide)exhibitedthehighestwear resistanceagainstSiC(with120grainsize).Thechangingofthewearratesisdegressive.Accordingtothe expectations the ZrO2/Y2O3 specimenswearoutrapidly.Aprogressivechangeofthewearratesisobserved.The restofthecoatings(Cr3C2-NiCr,Al2O3/TiO2,NiCrBSiandNiMoAl)hasnearlyalinearwearbehaviour.Theresults oftheweartestscanbebroughtintorelationwiththeadhesiontensilestrength(Table3)ofthesamecoatings.

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Acknowledgements ThisworkwasperformedwiththetechnicalsupportofBayerAGLeverkusen,IN-ATUWerkstofftechnik.This valuablesupportisgratefullyacknowledged. References 1. Gudenau,H.W.,Dahl,W.,Dinkov,P.&Scheiwe,M.,1991.Rechner-Simulationeinesthermoschockbeanspruchtenmetall-keramischenSchichtverbundes.Werkstoffe und Konstruktion, 5(2),p.105-117. 2. Dinkov,P.,1991.Beitrag zum Schutz von thermisch und mechanisch hoch belasteten Bauteiloberflaechen durch Verbundwerkstoffe, VDI-Fortschritt-Berichte,Reihe5:Grund-undWerkstoffe,216,VDI-Verlag,Duesseldorf. 3. Protogerakis,E.&Kreisel,K.1989.Metallische und oxidische thermische Spritzschichten, Bayer-Bericht,INATUWerkstofftechnik,IN-ZWS-W,Metallischer Oberflaechenschutz,Leverkusen,Sept.1989. 4. Elsing,R.,Heintz,H.-R.,Knotek,O.&Strompen,N.,1989?probabledecade.Eigenschaften thermisch gespritzter Metalloxid- und Oxidschichten; DVS98,p.99102. 5. Zografou,C.,Dhupia,G.S.,Kroenert,W.&Protogerakis,E.,1986.Microstructuralaspectsrelatedtothequality of thermally sprayed ceramic coatings; Journal des physique,suppl.2,Tome47,fevr.1986,p.171-175. 6. Dinkov,P.,2004b.Wearresistanceofcoatingswithapplicationinthechemicalplantengineering. In IV International Congress Mechanical Engineering Technologies04 inVarna,Scientific Proceedings of the ScientificTechnical Union of Mechanical Engineering,YearXI,Vol.5/73,Sec.3,September2004,p.225228. 7. Balting,U.,1990.Untersuchung plasmagespritzter Al2O3-Schicht-Substrat-Verbundsysteme mit Hilfe der Simulation, DVS-Verl., Schweisstechnische Forschungsberichte,Bd.37,Duesseldorf,1990. 8. Koerfer,M.,Gudenau,H.W.,Dinkov,P.&Scheiwe,M.,1990.Energie-undCO-GasrckgewinnungbeimLDProze KorrosionsproblemeundSpannungsbetrachtungenimAbhitzekessel.In6. Aachener Stahlkolloquium (ASK),12.-13.6.1990,Tagungsband,p.4.3-1/7. 9. Dinkov,P.,2003.Mechanicalpropertiesofthermalsprayedcoatingswithapplicationintheplantengineering. In RaDMI 2003, 3rd International Conference Research and Development in Mechanical Industry, 19-23 September2003,HercegNovi,SerbiaandMontenegro,A19,p.182-187. 10.Dinkov,P.,2004a.Investigationoftheadhesiontensilestrengthofthermalsprayedcoatingswithapplicationin thechemicalplantengineering. InScientificConferencewithInternationalParticipation Manufacturing and Management in the 21st Century, Ohrid,Rep.Macedonia,Sept.16-17,2004,p.110114.

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