Microstructure and wear behaviors of laser clad NiCr/Cr3C2-WS2 high temperature self-lubricating wear-resistant composite coating

The high temperature self-lubricating wear-resistant NiCr/Cr₃C₂-30%WS₂ coating and wear-resistant NiCr/Cr₃C₂ coating were fabricated on 0Cr18Ni9 austenitic stainless steel by laser cladding. Phase constitutions and microstructures were investigated, and the tribological properties were evaluated using a ball-on-disc wear tester under dry sliding condition at room-temperature (17 °C), 300 °C and 600 °C, respectively. Results indicated that the laser clad NiCr/Cr₃C₂ coating consisted of Cr₇C₃ primary phase and γ-(Fe,Ni)/Cr₇C₃ eutectic colony, while the coating added with WS₂ was mainly composed of Cr₇C₃ and (Cr,W)C carbides, with the lubricating WS₂ and CrS sulfides as the minor phases. The wear tests showed that the friction coefficients of two coatings both decrease with the increasing temperature, while the both wear rates increase. The friction coefficient of laser clad NiCr/Cr₃C₂-30%WS₂ is lower than the coating without WS₂ whatever at room-temperature, 300 °C, 600 °C, but its wear rate is only lower at 300 °C. It is considered that the laser clad NiCr/Cr₃C₂-30%WS₂ composite coating has good combination of anti-wear and friction-reducing capabilities at room-temperature up to 300 °C.     

Preparation and properties of electroless Ni-P-SiO2 composite coatings

Dispersible SiO₂ nanoparticles were co-deposited with electroless Ni-P coating onto AISI-1045 steel substrates in the absence of any surfactants in plating bath. The resulting Ni-P/nano-SiO₂ composite coatings were heat-treated for 1 h at 200 °C, 400 °C, and 600 °C, respectively. The hardness and wear resistance of the heat-treated composite coatings were measured. Moreover, the structural changes of the composite coatings before and after heat treatment were investigated by means of X-ray diffraction (XRD), while their elemental composition and morphology were analyzed using an energy dispersive spectrometer (EDS) and a scanning electron microscope (SEM). Results show that co-deposited SiO₂ particles contributed to increase the hardness and wear resistance of electroless Ni-P coating, and the composite coating heat-treated at about 400 °C had the maximum hardness and wear resistance.     

Microstructure and dry-sliding wear resistance of PTA clad (Cr, Fe)7C3/γ-Fe ceramal composite coating

A wear resistant (Cr, Fe)₇C₃/γ-Fe ceramal composite coating was fabricated on substrate of a 0.45%C carbon steel by plasma transferred arc (PTA) cladding process using the Fe-Cr-C elemental powder blends. The microstructure, microhardness and dry-sliding wear resistance of the coating were evaluated. Results shown that the plasma transferred arc clad ceramal composite coating has a rapidly solidified microstructure consisting of blocky primary (Cr, Fe)₇C₃ and the inter-blocky (Cr, Fe)₇C₃/γ-Fe eutectics and is metallurgically bonded to the 0.45%C carbon steel substrate. The ceramal composite coating has high hardness and excellent wear resistance under dry sliding wear test condition.     

Double layer oxidation resistant coating for carbon fiber reinforced silicon carbide matrix composites

Double layer coatings, with celsian-Y₂SiO₅ as inner layer and Y₂Si₂O₇ as outer layer, were prepared by microwave sintering on the surface of carbon fiber reinforced silicon carbide matrix composite. Both celsian, Y₂SiO₅ and Y₂Si₂O₇ were synthesized by in situ method using BAS glass, Y₂O₃ and SiO₂ as staring materials. The sintering temperature was 1500 °C, and little damage was induced to the composite. The composition and micrograph of the fired coating were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The oxidation and thermal shock resistance of samples with doubled-layered coating were characterized at 1400 °C in air. After 150 min oxidation and thermal cycling between 1400 °C and room temperature for 15 times, the weight loss of double layer-coated sample was 1.22% and there were no cracks in the coating.     

Influence of heat treatment on tribological properties of electroless Ni-P and Ni-P-Al2O3 coatings on Al-Si casting alloy

Evolution of tribological properties of electroless Ni-P and Ni-P-Al₂O₃ coating on an Al-10Si-0.3Mg casting alloy during heat treatment is investigated in this work. The pre-treated substrate was plated using a bath containing nickel hypophosphite, nickel lactate and lactic acid. For preparation of fiber-reinforced coating Al₂O₃ Saffil fibers pre-treated in demineralised water were used. The coated samples were heat treated at 400-550 °C/1-8 h. Tribological properties were studied using the pin-on-disc method. It is found that the best coating performance is obtained using optimal heat treatment regime (400 °C/1 h). Annealing at higher temperatures (450 °C and above) leads to the formation of intermetallic compounds that reduce the coating wear resistance. The reason is that the intermetallic phases adversely affect the coating adherence to the substrate. The analysis of wear tracks proves that abrasion is major wear mechanism, however due to the formed intermetallic sub-layers, partial coating delamination may occur during the pin-on-disc test on the samples annealed at 450 °C and above. It was found that fiber reinforcement reduces this scaling and increases wear resistance of coatings as compared to the non-reinforced Ni-P coatings.     

Corrosive behavior of chromium carbide-based films formed on steel using a filtered cathodic vacuum arc system

The formation of chromium carbide-based hard-coatings on steels using a 90°-bend filtered cathodic vacuum arc (FCVA) has extensive industrial applications; such coatings are free of macroparticles and exhibit excellent characteristics. In this investigation, a working pressure of C₂H₂/Ar was adopted to synthesize amorphous chromium carbide film (a-C:Cr) and crystalline chromium carbide film (cryst-Cr₃C₂) from a Cr target (99.95%) at 500 °C under a substrate voltage of −50 V. The corrosion behavior of a-C:Cr coated on steel (a-C:Cr/steel) and cryst-Cr₃C₂ coated on steel (cryst-Cr₃C₂/steel) were compared in terms of open-circuit potentials (OCP) and polarization resistance (R_p) in an aerated 3.5 wt% NaCl aqueous solution, as determined by electrochemical impedance spectroscopy (EIS). The XRD results indicated that the transformation of a-C:Cr to cryst-Cr₃C₂ is distinct as the working pressure declines from 1.2 × 10⁻² to 2.9 × 10⁻³ Torr. The OCP of a-C:Cr/steel and cryst-Cr₃C₂/steel resemble each other and both assembly are nobler than uncoated steel. The R_p of the coatings exceeds that of the uncoated steel. The SEM observation and the EIS results demonstrate that the cryst-Cr₃C₂/steel more effectively isolates the defects than dose a-C:Cr/steel.     

A study of TaxC1−x coatings deposited on biomedical 316L stainless steel by radio-frequency magnetron sputtering

In this paper, Ta_xC_1−x coatings were deposited on 316L stainless steel (316L SS) by radio-frequency (RF) magnetron sputtering at various substrate temperatures (T_s) in order to improve its corrosion resistance and hemocompatibility. XRD results indicated that T_s could significantly change the microstructure of Ta_xC_1−x coatings. When T_s was <150 °C, the Ta_xC_1−x coatings were in amorphous condition, whereas when T_s was ≥150 °C, TaC phase was formed, exhibiting in the form of particulates with the crystallite sizes of about 15-25 nm (T_s = 300 °C). Atomic force microscope (AFM) results showed that with the increase of T_s, the root-mean-square (RMS) values of the Ta_xC_1−x coatings decreased. The nano-indentation experiments indicated that the Ta_xC_1−x coating deposited at 300 °C had a higher hardness and modulus. The scratch test results demonstrated that Ta_xC_1−x coatings deposited above 150 °C exhibited good adhesion performance. Tribology tests results demonstrated that Ta_xC_1−x coatings exhibited excellent wear resistance. The results of potentiodynamic polarization showed that the corrosion resistance of the 316L SS was improved significantly because of the deposited Ta_xC_1−x coatings. The platelet adhesion test results indicated that the Ta_xC_1−x coatings deposited at T_s of 150 °C and 300 °C possessed better hemocompatibility than the coating deposited at T_s of 25 °C. Additionally, the hemocompatibility of the Ta_xC_1−x coating on the 316L SS was found to be influenced by its surface roughness, hydrophilicity and the surface energy.     

Modification of tribology and high-temperature behavior of Ti-48Al-2Cr-2Nb intermetallic alloy by laser cladding

In order to improve the tribology and high-temperature oxidation properties of the Ti-48Al-2Cr-2Nb intermetallic alloy simultaneously, mixed NiCr-Cr₃C₂ precursor powders had been investigated for laser cladding treatment to modify wear and high-temperature oxidation resistance of the material. The alloy samples were pre-placed with NiCr-80, 50 and 20%Cr₃C₂ (wt.%), respectively, and laser treated at the same parameters, i.e., laser output power 2.8 kW, beam scanning speed 2.0 mm/s, beam dimension 1 mm × 18 mm. The treated samples underwent tests of microhardness, wear and high-temperature oxidation. The results showed that laser cladding with different constitution of mixed precursor NiCr-Cr₃C₂ powders improved surface hardness in all cases. Laser cladding with NiCr-50%Cr₃C₂ resulted in the best modification of tribology and high-temperature oxidation behavior. X-ray diffraction (XRD), optical microscope (OM), scanning electron microscopy (SEM) and energy-dispersive spectrometer (EDS) analyses indicated that the formation of reinforced Cr₇C₃, TiC and both continuous and dense Al₂O₃, Cr₂O₃ oxide scales were supposed to be responsible for the modification of the relevant properties. As a result, the present work had laid beneficial surface engineering foundation for TiAl alloy applied as future light weight and high-temperature structural candidate materials.     

Structure and elastic recovery of Cr-C:H films deposited by a reactive magnetron sputtering technique

Cr-containing hydrogenated amorphous carbon (Cr-C:H) films were deposited on silicon substrates using a DC reactive magnetron sputtering with Cr target in an Ar and C₂H₂ gas mixture. The composition, bond structure, mechanical hardness and elastic recovery of the films were characterized using energy dispersive X-ray spectroscopy, X-ray photoelectron spectroscopy, Raman spectroscopy and nano-indentation. The film tribological behavior was also studied by a ball-on-disc tribo-tester. The results showed that the films deposited at low C₂H₂ flow rate (<10 sccm) presented a feature of composite Cr-C:H structure, which consisted of hard brittle chromium carbide phases and amorphous hydrocarbon phase, and thus led to the observed low elastic recovery and poor wear resistance of the films. However, the film deposited at high C₂H₂ flow rate (40 sccm) was found to present a typical feature of polymer-like a-C:H structure containing a large amount of sp³ C-H bonds. As a result, the film revealed a high elastic recovery, and thus exhibited an excellent wear resistance.     

Preparation and high-temperature properties of Au nano-particles doped α-Al2O3 composite coating on TiAl-based alloy

Au nano-particles doped α-Al₂O₃ composite coatings were successfully prepared on TiAl-based alloy by electrodeposition, using the Al₂O₃ sols with minor addition of HAuCl₄ solution. The even distribution of Au nano-particles (<2.0 wt.%) in the α-Al₂O₃ matrix has been observed. Isothermal oxidation tests of the samples coated with the as-prepared novel coatings at 900 °C in static air for 200 h shown that the oxygen inward diffusion can be effectively suppressed to a low level. The results of high-temperature cyclic oxidation test at 900 °C in air revealed that the oxidation and spallation resistance of TiAl-based alloy were improved significantly under thermal cycling. In the as-prepared coatings, cracks were shielded by means of crack bridging and the fracture resistance of the formed scales can be improved by toughening effects of the composite structure. Surface scratching tests after the cyclic oxidation exhibited that the adhesion of the formed composite scale on TiAl-based alloy was remarkably improved by the Au nano-particles doped α-Al₂O₃ composite coating.     

Tribological properties of heat-treated electroless Ni-P coatings on AZ91 alloy

Influence of heat treatment regime on adhesion and wear resistance of Ni-P electroless coating on AZ91 magnesium alloy is investigated in this work. The pretreated substrate was plated using a bath containing nickel sulphate, sodium hypophosphite and sodium acetate as main constituents. The coated samples were heat treated at 400-450 °C for 1-8 h. Adhesion of coating was estimated from the scratch test with an initial load of 8.80 N. Wear resistance was studied using the pin-on-disc method. It was found that there is no significant dependence of the coating wear resistance on heat treatment regime, as the formation of Al-Ni intermetallic sub-layers that reduce coating adhesion is limited to regions where Al₁₇Mg₁₂ phase is present in the substrate. Moreover, the coating shows good sliding properties due to the formation of oxide glazes in the wear track.     

High-temperature oxidation resistance and magnetic properties of Si-doped Sm2Co17-type magnets at 500 °C

The high-temperature oxidation resistance and magnetic properties of Si-doped Sm₂Co₁₇-type magnets at 500 °C were systematically investigated. The Sm(Co_0.76, Fe_0.1, Cu_0.1, Zr_0.04)₇Si_x (x=0–0.6) magnets were prepared by the conventional powder metallurgical technique. It is found that the addition of silicon in the Sm₂Co₁₇-type magnet can remarkably improve its oxidation resistance. Moreover, a small amount of silicon addition can also increase its high-temperature intrinsic coercivity. A maximum intrinsic coercivity of 6.7 kOe at 500 °C was obtained for the Sm₂Co₁₇-type magnet with Si content x=0.4, whose high-temperature maximum energy product loss was about 2.5 times smaller than pure Sm₂Co₁₇-type magnet after oxidation at 500 °C for 100 h, indicating the enhanced oxidation resistance. Its corresponding Curie temperature and saturation magnetization are about 723.9 °C and 7.4 kG, respectively.     

The microstructure and specific properties of La/HAP composite powder and its coating

La/HAP composite powder, a novel bioactive material, was prepared using co-precipitation method. The La/HAP coating was obtained for the first time through the dip-coating method, starting from the sols of La/HAP and TiO₂ particles. The compositions and coating of as-produced La/HAP composite powder sintered at temperatures from 300 to 750 °C were analyzed by means of X-ray diffraction (XRD). The changes of the ion groups in as-prepared La/HAP composite powder were characterized by using Fourier transform infrared (FTIR) spectroscopy. Their surface morphologies were observed by means of scanning electron microscope (SEM). The results show that the La/HAP composite powder has higher thermostability than pure HAP powder and La can refine HAP particle and restrain the decomposition of HAP. Consequently, in coating process the heat-treatment temperature is lower (750 °C) using the synthesized La/HAP powder than that using pure HAP (900 °C). The La/HAP coating mainly contains HAP, TiP or Ti₃P₅ and TiO₂ phases as well as a little CaTiO₃ crystal, a very ideal composition to enhance bioactivity of biomaterials. These unique properties of the La/HAP composite powder are beneficial to enhance the strength and bioactivity of coating when it is used as a starting material in coating process.     

Chemical reactivity of PVD-coated WC-Co tools with steel

The chemical reactivity of CrN, ZrN, TiC_xN_1−x and naCo^® PVD coatings on a WC-Co cemented carbide substrate with steel has been evaluated by means of the static interaction couples technique. Diffusion experiments with coated and uncoated tools were carried out at 900, 1100 and 1300 °C in order to establish the maximum temperature at which the substrate-coating-workpiece combinations are chemically stable. Computational equilibrium thermodynamics was used to identify the interaction products formed at elevated temperature and the chemical solubility of the different coating materials into iron. A metallic (Fe, Co) fcc solid solution was identified at the steel side of the interface from 1100 °C on for all the coated tools and from 900 °C for the uncoated carbide. In addition to this interaction product, the ?-carbide was identified at 1300 °C on the WC-Co side of the interface. Both of the experimental findings and thermodynamic equilibrium solubility calculations demonstrated that the PVD-coated WC-Co tools exhibit a lower chemical reactivity with respect to the uncoated tools.     

SiC/SiO2 coating for improving the oxidation resistive property of carbon nanofiber

The SiC/SiO₂ deposition was performed to improve the oxidation resistive properties of carbon nanofiber (CNF) from electrospinning at elevated temperatures through sol-gel process. The stabilized polyacrylonitrile (PAN) fibers were coated with SiO₂ followed by heat treatment up to 1000 and 1400 °C in an inert argon atmosphere. The chemical compositions of the CNFs surface heat-treated were characterized as C, Si and O existing as SiC and SiO₂ compounds on the surface. The uniform and continuous coating improved the oxidation resistance of the carbon nanofibers. The residual weight of the composite was 70-80% and mixture of SiC, SiO₂ and some residual carbon after exposure to air at 1000 °C.     

Influence of temperature on structure as well as adhesion and friction and wear behavior of hydrogenated carbon nitride films prepared on silicon substrate

Hydrogenated-carbon nitride (CN_x:H) films were synthesized on silicon substrate in a large quantity by the pyrolysis of ethylenediamine in a temperature range of 700-950 °C. The influence of temperature on the morphology, structure, adhesion to substrate, and friction and wear behavior of CN_x:H films was investigated. It has been found that CN_x:H films obtained at 700 °C and 800 °C are amorphous, and those prepared at 900 °C and 950 °C consist of carbon nitride nanocrystal. Besides, CN_x:H film sample obtained at 700 °C has the maximum N content of 9.1 at.% but the poorest adhesion to Si substrate, while the one prepared at 900 °C has the lower N content and the highest adhesion to substrate. As a result, nanocrystalline CN_x:H (nc-CN_x:H) film synthesized at 900 °C possesses the best wear resistance when slides against stainless steel counterpart. N atom is incorporated into the graphitic network in three different bonding forms, and their relative content is closely related to temperature, corresponding to different adhesion as well as friction and wear behavior of the films obtained at different temperatures. Furthermore, the friction coefficient and antiwear life of as-deposited CN_x:H films vary with varying deposition temperature and thickness, and the film with thickness of 1.3 μm, obtained at 900 °C, has the longest antiwear life of over 180,000 s.     

Formation of Cr-modified silicide coatings on a Ti-Nb-Si based ultrahigh-temperature alloy by pack cementation process

Cr-modified silicide coatings were prepared on a Ti-Nb-Si based ultrahigh temperature alloy by Si-Cr co-deposition at 1250 °C, 1350 °C and 1400 °C for 5-20 h respectively. It was found that both coating structure and phase constituents changed significantly with increase in the co-deposition temperature and holding time. The outer layers in all coatings prepared at 1250 °C for 5-20 h consisted of (Ti,X)₅Si₃ (X represents Nb, Cr and Hf elements). (Ti,X)₅Si₄ was found as the only phase constituent in the intermediate layers in both coatings prepared at 1250 °C for 5 and 10 h, but the intermediate layers in the coatings prepared at 1250 °C for 15 and 20 h were mainly composed of (Ti,X)₅Si₃ phase that was derived from the decomposition of (Ti,X)₅Si₄ phase. In the coating prepared at 1350 °C for 5 h, single (Ti,X)₅Si₃ phase was found in its outmost layer, the same as that in the outer layers in the coatings prepared at 1250 °C; but in the coatings prepared at 1350 °C for 10-20 h, (Nb_1.95Cr_1.05)Cr₂Si₃ ternary phase was found in the outmost layers besides (Ti,X)₅Si₃ phase. In the coatings prepared at 1400 °C for 5-20 h, (Nb_1.95Cr_1.05)Cr₂Si₃ ternary phase was the single phase constituent in their outmost layers. The phase transformation (Ti,X)₅Si₄ → (Ti,X)₅Si₃ + Si occurred in the intermediate layers of the coatings prepared at 1350 and 1400 °C with prolonging co-deposition time, similar to the situation in the coatings prepared at 1250 °C for 15 and 20 h, but this transformation has been speeded up by increase in the co-deposition temperature. The transitional layers were mainly composed of (Ti,X)₅Si₃ phase in all coatings. The influence of co-deposition temperature on the diffusion ability of Cr atoms was greater than that of Si atoms in the Si-Cr co-deposition processes investigated. The growth of coatings obeyed inverse logarithmic laws at all three co-deposition temperatures. The Si-Cr co-deposition coating prepared at 1350 °C for 10 h showed a good oxidation resistance due to the formation of SiO₂ and Nb, Cr-doped TiO₂ scale after oxidation at 1250 °C for 10 h.     

Effect of annealing on phase composition,structural and magnetic properties of Sm-Co based nanomagnetic material synthesized by sol-gel process

Sm-Co based nanomagnetic material was synthesized by means of a Pechini-type sol-gel process. In this method, a suitable gel-precursor was prepared using respective metal salts and complexing agent such as citric acid. The gel-precursor was dried at 300 °C and then subjected to various reductive annealing temperatures: 350, 500 and 600 °C. The nanopowders so obtained were characterized for their structure, phase composition and magnetic properties. FT-IR studies on the gel-precursor showed the binding of metal cations with the citrate molecules in the form of metal-citrate complex. The gel-precursor, which was annealed at 350 °C showed the presence of both meta-stable cobalt carbide (Co₂C, Co₃C) and Co₃O₄ phases; while the sample annealed at 500 °C indicated the sign of SmCo₅ phase. Upon increasing the reductive annealing temperature to 600 °C, crystalline phase such as fcc-Co and Sm₂C₃ were formed prominently. FE-SEM analysis revealed the change in sample morphology from spherical to oblate spheres upon increasing the annealing temperature. VSM measurements demonstrated ferromagnetic nature at room temperature for all the nanopowders obtained irrespective of their after reductive annealing temperature.     

Study on Fe-Al-Si in situ composite coating fabricated by laser cladding

Fe-Al-Si in situ composite coating was fabricated on the surface of ASTM A283Gr.D steel by laser cladding with the preplaced powder. The influence of powder composition, laser power and scanning speed on microstructure, microhardness and wear resistance were investigated in this paper. The results show that Fe-Al-Si in situ composite coating with the good metallurgical bond mainly consists of Fe, SiO₂ and Al₂Fe₃Si₄ intermetallic compound. With the increase of laser power and scanning speed, the grain size of coating gets the minimum value. With the increase of laser power and scanning speed, microhardness and wear resistance both get the peak vaule, and their value are three times and 3.5 times those of substrate, respectively. The optimum parameters are followed as: the ratio of the preplaced composite powder: 8:1:1, laser power: 1600 W and scanning speed: 400 mm/min.     

High temperature oxidation behavior of interconnect coated with LSCF and LSM for solid oxide fuel cell by screen printing

The current study examined the effect of La_0.6Sr_0.4Co_0.2Fe_0.8O₃ (LSCF) and La_0.7Sr_0.3MnO₃ (LSM) coatings on the electrical properties and oxidation resistance of Crofer22 APU at 800 °C hot air. LSCF and LSM were coated on Crofer22 APU by screen printing and sintered over temperatures ranging from 1000 to 1100 °C in N₂. The coated alloy was first checked for compositions, morphology and interface conditions and then treated in a simulated oxidizing environment at 800 °C for 200 h. After measuring the long-term electrical resistance, the area specific resistance (ASR) at 800 °C for the alloy coated with LSCF was less than its counterpart coated with LSM. This work used LSCF coating as a metallic interconnect to reduce working temperature for the solid oxide fuel cell.