INFLUENCE OF HVOF COATING ON THE FATIGUE STRENGTH OF 15-5 PH STAINLESS STEEL

Structural component failures due to cyclic loading are associated to surface damage of materials and its interaction with environment. Fatigue failure occurs with stresses below the yield strength of each material and is a result of crack initiation and propagation. In aeronautical components is an important parameter to be considered in project, as well as the corrosion and wear resistance. Thermally sprayed HVOF coatings have been considered to replace galvanic chromium deposits with comparable performance for wear and corrosion resistance. The aim of present research is to study the influence of WC-13Co-4Cr applied by HVOF, on the axial fatigue strength of 15-5 PH stainless steel. The shot peening treatment was used to restore fatigue performance.

Caracterização do aço inoxidável ASTM A743 CA6NM e do seu revestimento de WC-10Co-4Cr aspergido termicamente por HVOF

Pós-graduação em Engenharia Mecânica - FEG

Effect of electroless nickel interlayer on the fatigue strength of chromium electroplated AISI 4340 steel

Deposition of wear-resistant hard chromium plating leads to a decrease in the fatigue strength of the base material. Despite the effective protection against wear and corrosion, fatigue life and environmental requirements result in pressure to identify alternatives or to improve conventional chromium electroplating mechanical characteristics. An interesting, environmentally safer and cleaner alternative for the replacement of hard chronic plating is tungsten carbide thermal spray coating, applied by high velocity oxyfuel (HVOF) process.To improve the fatigue strength of aeronautical steel chromium electroplated, shot peening is a successfully used method. Multiple lacer systems of coatings are considered to have larger resistance to crack propagation in comparison with simple layer.The aim of this study was to analyze the effect of nickel underplate on the fatigue strength of hard chromium plated AISI 4340 steel in two mechanical conditions: HRc 39 and HRc 52.Rotating bending fatigue tests results indicate that the clectroless nickel plating underlayer is responsible for the increase in fatigue strength of AISI 4340 steel chromium electroplated. This behavior may be attributed to the largest toughness/ductility and compressive residual stresses which, probably, arrested or delayed the inicrocrack propagation from the hard chromium external layer. The compressive residual stress field (CRSF) induced by the electroplating process was determined by X-ray diffraction method. The evolution of fatigue strength compressive residual stress field CRSF and crack sources are discussed and analyzed by SEM. (c) 2006 Elsevier Ltd. All rights reserved.

Effects of surface treatments on the fatigue strength of AISI 4340 aeronautical steel

Internal residual stresses significantly influence the fatigue strength of coated materials. It is well known that chromium plating is the most used electrodeposited coating for important industrial applications. However, pressure to identify alternatives or to improve the chromium electroplating process have increased in recent years, related to the reduction in fatigue strength of the base material and to environmental requirements. The high efficiency and fluoride free hard chromium electroplating there called accelerated) is an improvement to the conventional process. One environmentally safer and cleaner alternative to hard chromium plating is tungsten carbide thermal spray coating applied by the High Velocity Oxy-Fuel (HVOF) process. To increase the fatigue strength of chromium plated materials, coating thickness and microcracks density are important parameters to be controlled. Techniques as compressive residual stresses induced by shot peening and multilayers, are also used. The aim of this study was to analyse the effects on AISI 4340 steel, in the rotating bending fatigue behaviour, of the: tungsten carbide thermal spray coating applied by HP/HVOF process; chemical nickel underplate, and shot peening process applied before coating deposition, in comparison to hard chromium electroplatings. Rotating bending fatigue test results indicate better performance for the conventional hard chromium plating in relation to the accelerated hard chromium electroplating. Tungsten carbide thermal spray coating and accelerated hard chromium plate over nickel resulted in higher fatigue strength when compared to samples conventional or accelerated hard chromium plated. Shot peening showed to be an excellent alternative to increase fatigue strength of AISI 4340 steel hard chromium electroplated. (C) 2001 Elsevier B.V. Ltd. All rights reserved.

An investigation on sliding wear behavior of PVD coatings

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Effect of WC-10%Co-4%Cr coating on the Ti-6Al-4V alloy fatigue strength

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Carbon fiber non-crimp multi-axial reinforcement and epoxy mono-component system composite: fatigue behavior

Fiber reinforced polymer composites have been widely applied in the aeronautical field. However, composite processing, which uses unlocked molds, should be avoided in view of the tight requirements and also due to possible environmental contamination. To produce high performance structural frames meeting aeronautical reproducibility and low cost criteria, the Brazilian industry has shown interest to investigate the resin transfer molding process (RTM) considering being a closed-mold pressure injection system which allows faster gel and cure times. Due to the fibrous composite anisotropic and non homogeneity characteristics, the fatigue behavior is a complex phenomenon quite different from to metals materials crucial to be investigated considering the aeronautical application. Fatigue sub-scale specimens of intermediate modulus carbon fiber non-crimp multi-axial reinforcement and epoxy mono-component system composite were produced according to the ASTM 3039 D. Axial fatigue tests were carried out according to ASTM D 3479. A sinusoidal load of 10 Hz frequency and load ratio R = 0.1. It was observed a high fatigue interval obtained for NCF/RTM6 composites. Weibull statistical analysis was applied to describe the failure probability of materials under cyclic loads and fractures pattern was observed by scanning electron microscopy. (C) 2010 Published by Elsevier Ltd.

Evaluation of WC-10Ni thermal spray coating with shot peening on the fatigue strength of AISI 4340 steel

Fatigue failure is a result of a crack initiation and propagation, in consequence of a cyclical load. In aeronautical components as landing gear the fatigue strength is an important parameter to be considered in project, as well as the corrosion and wear resistance.The thermal sprayed HVOF technology it's normally used to protect components against wear and corrosion, and are being considerate an alternative to replace chromium by the aeronautical industry. With respect to fatigue life, the HVOF technique induces residual stress on the interface. In the case of tensile residual stresses, the initiation and propagation phases of fatigue process are accelerated; on the other hand, compressive residual stresses close to the surface may increase fatigue life. The technique to improve the coated materials fatigue strength is the shot peening process, which induces residual stress in the surface in order to delay the nucleation and propagation process.The aim of present study is to compare the influence of WC-10 Ni coating applied by HVOF on the fatigue strength of AISI 4340 steel, with and without shot peening. S-N curves were obtained in axial fatigue tests for material base, and tungsten carbide coated specimens. (C) 2010 Published by Elsevier Ltd.

High-velocity oxyfuel Cr3C2-NiCr replacing hard chromium coatings

Comparative wear and corrosion properties of Cr3C2-NiCr (CC-TS) (a high-velocity oxyfuel [HVOF]) and hard chromium (HC) coating's obtained on a steel substrate have been studied. The structural characterization was done before and after measurements by optical microscopy, scanning electron microscopy, and scanning white light interferometry. Wear and corrosion properties were evaluated by ball on disk (ASTM G99-90), rubber wheel (ASTM G65-91), and electrochemical measurements of open circuit and polarization curves. The best corrosion and wear resistance was for the CC-TS obtained by HVOF. The open-circuit potential values measured for both samples after 18 h of immersion we're: -0.240 and -0.550 V, respectively, for CC-TS and HC, versus Ag/AgCl,KClsat. Three orders of magnitude lower volume loss were found for CC-TS (HVOF) after friction tests compared with HC.

The influence of gun transverse speed on electrochemical behaviour of thermally sprayed Cr3C2-NiCr coatings in 0.5 M H2SO4 solution

In the present study, different types of 75% Cr3C2-25% NiCr coatings were applied on a steel substrate by means of high velocity oxygen fuel spraying (HVOF), and studied using ac and dc electrochemical measurements in an aerated and unstirred 0.5 M H2SO4 solution. Structural characterization was determined before and after electrochemical tests. Differences between all sprayed systems are related to the gun transverse speed and number of deposited layers, which strongly affected the electrochemical characteristics of the coated steels. The coating obtained with a higher torch speed showed better resistance against corrosion. The electrochemical impedance results were analyzed using an equivalent circuit where porosity of the coatings and substrate oxidation were considered. (C) 2003 Elsevier Ltd. All rights reserved.

Electrochemical behavior of thermally sprayed stainless steel coatings in 3.4% NaCl solution

Four types of stainless steel coatings prepared by a high velocity oxy-fuel spraying system (HVOF) were studied. Differences among coated steels were related to the spraying parameters, which influenced the behavior of the samples against the corrosion. The electrochemical behavior of the stainless steel coatings was strongly influenced by porosity, the presence of micro- and macro-cracks, and also of un-melted particles. Once the electrolyte reached the steel substrate via these defects, the galvanic pair formed between the coating and substrate-accelerated corrosion, leading to the depletion of the coating. (C) 2004 Elsevier Ltd. All rights reserved.

Effects of thickness coating on the electrochemical behaviour of thermal spray Cr3C2-NiCr coatings

Thermally sprayed HVOF coatings are increasingly being used in industrial applications where high wear and corrosion resistance are needed [1,2]. In this paper, electrochemical ac and de experiments were used in order to obtain the corrosion resistance of coated steel with different numbers of Cr3C2-NiCr layers. This work has been performed in order to determine the role of coating thickness in the corrosion behaviour of a steel protected with cermet thermally sprayed coatings. It is known that a thicker layer protects better against corrosion when a metallic coating is evaluated. But cermet coatings, such as Cr3C2-NiCr, contain higher levels of porosity and residual stresses than metallic coatings, which really could influence the corrosion resistance of the deposited layer. Electrochemical measurements, such as Open-Circuit Potential (E-Osubset of), Polarisation Resistance (RP) and Cyclic Voltammetry (CV), were performed in an aerated 3.4 NaCI media (%wt.). Electrochemical Impedance Measurements (EIS) were also done in order to obtain a mechanism that explains the corrosion process. Structural Characterisation was carried out by means of Optical and Scanning Electron Microscopes (OM, SEM) with an Energy Dispersive Spectrometry analyser (EDS). Results show that the corrosion resistance of the complete system is mainly influenced by the substrate behaviour. The application of a higher number of deposited layers did not substantially increase their anticorrosive properties. Stress generation during the spraying deposition process plays an important role in the behaviour of the coated steel against corrosion phenomena. (C) 2002 Elsevier B.V. B.V All rights reserved.

Electrochemical behaviour of thermally sprayed Cr3C2-NiCr coatings in 0.5 M H2SO4 media

The electrochemical behaviour of coated Cr3C2-NiCr steel in aerated 0.5 M H2SO4 solution was studied by means of electrochemical a.c. and d.c. measurements. A complete structural characterization of the coated steel before and after electrochemical tests was also carried out to access the corrosion mechanism of coated steel, electrolyte penetration through the coating, and to confirm the results obtained using electrochemical techniques. Two types of Cr3C2-NiCr coatings produced by a high velocity oxy-fuel spraying system (HVOF) were studied. Differences between coated steels are related to the spraying parameters reflecting their behaviour against corrosion phenomena. The electrochemical behaviour of the coated steel was strongly influenced by porosity and the presence of microcracks in the coating. Once the electrolyte reaches the steel substrate, it corrodes in a galvanic manner resulting in coating detachment from the steel.

Electrochemical and structural characterization of heat-treated Cr3C2-NiCr coatings

The influence of heat-treatments on the electrochemical behavior of thermal spray Cr3C2-NiCr coatings prepared by high velocity oxygen fuel (HVOF) was studied in NaCl solution, at 25 degrees C, using open-circuit potential (E-OC) and electrochemical impedance spectroscopy (EIS) measurements. Coating characterization were performed before and after the heat-treatments and electrochemical tests by scanning electron microscopy, X-ray diffraction, and Auger electron spectroscopy. In addition to the changes in the original powder composition occurring during HVOF process, heat-treatment performed at 450 degrees C caused no significant changes in electrochemical response compared with untreated sample, and at 760 degrees C the main difference was the formation of a thin and defective layer of Cr2O3 at the coating surface, which increased the total impedance at the first day of immersion. Higher influence on the electrochemical was noted for samples treated at 880 degrees C, which also showed higher E-OC and total impedance, and lower corrosion current. This behavior was interpreted considering the formation of a chromium oxide layer on the coating surface, dissolution and decomposition of smaller carbide particles and their surface enrichment with Cr due to C diffusion and dissolution into the matrix, and possible Ni, Cr, and Fe diffusion to coating/substrate interface. (c) 2006 the Electrochemical Society.

Cr3C2-NiCr and WC-Ni thermal spray coatings as alternatives to hard chromium for erosion-corrosion resistance

Cr3C2-NiCr and WC-Ni coatings are widely used for wear applications at high and room temperature, respectively. Due to the high corrosion resistance of NiCr binder, Cr3C2-NiCr coatings are also used in corrosive environments. The application of WC-Ni coatings in corrosive media is 14 not recommended due to the poor corrosion resistance of the (pure Ni) metallic matrix. It is well known that the addition of Cr to the metallic binder improves the corrosion properties. Erosion-corrosion performance of thermal spray coatings is widely influenced by ceramic phase composition, the size of ceramic particles and also the composition of the metallic binder. In the present work, two types of HVOF thermal spray coatings (Cr3C2-NiCr and WC-Ni) obtained with different spray conditions were studied and compared with conventional micro-cracked hard chromium coatings. Both as-sprayed and polished samples were tested under two erosion-corrosion conditions with different erosivity. Tungsten carbide coatings showed better performance under the most erosive condition, while chromium carbide coatings were superior under less erosive conditions. Some of the tungsten carbide coatings and hard chromium showed similar erosion-corrosion behaviour under more and less erosive conditions. The erosion-corrosion and electrochemical results showed that surface polishing improved the erosion-corrosion properties of the thermally sprayed coatings. The corrosion behaviour of the different coatings has been compared using Electrochemical Impedance Spectroscopy (EIS) and polarization curves. Total material loss due to erosion-corrosion was determined by weight loss measurements. An estimation of the corrosion contribution to the total weight loss was also given. (c) 2007 Elsevier B.V. All rights reserved.