Next Article in Journal
Current Status of Image Recognition Technology in the Field of Corrosion Protection Applications
Previous Article in Journal
A3B Zn(II)-Porphyrin-Coated Carbon Electrodes Obtained Using Different Procedures and Tested for Water Electrolysis
Previous Article in Special Issue
Influence of Graphite and Zirconia Addition on the Tribological Properties of Plasma-Sprayed Alumina Coatings
 
 
Search for Articles:
Title / Keyword
Author / Affiliation / Email
Journal
Article Type
 
 
Advanced Search
 
Section
Special Issue
Volume
Issue
Number
Page
 
Journals
Coatings
Volume 14
Issue 8
10.3390/coatings14081049
coatings-logo
Submit to this Journal Review for this Journal Propose a Special Issue
► Article Menu

Article Menu

share Share announcement Help format_quote Cite question_answer Discuss in SciProfiles thumb_up
...
Endorse textsms
...
Comment
first_page
settings
Order Article Reprints
Font Type:
Arial Georgia Verdana
Font Size:
Aa Aa Aa
Line Spacing:
Column Width:
Background:
Article

The Influence of Distance Pulsed Plasma Treatment on the Structure and Properties of Detonation Coatings from Eutectic Alloy Fe-TiB2-CrB2

by
Bauyrzhan Rakhadilov
1,2,
Dauir Kakimzhanov
2,3,*,
Ainur Seitkhanova
4,5,
Aidar Kengesbekov
3,6 and
Nazerke Muktanova
2,3
1
Research Center “Surface Engineering and Tribology”, Sarsen Amanzholov East Kazakhstan University, Ust-Kamenogorsk 070000, Kazakhstan
2
PlasmaScience LLP, Ust-Kamenogorsk 070010, Kazakhstan
3
Daulet Serikbaev East Kazakhstan Technical University, Ust-Kamenogorsk 070002, Kazakhstan
4
Pavlodar Pedagogical University, Pavlodar 140000, Kazakhstan
5
Engineering Centre “Innotechmash”, Ust-Kamenogorsk 070000, Kazakhstan
6
Institute of Composite Materials, Ust-Kamenogorsk 070000, Kazakhstan
*
Author to whom correspondence should be addressed.
Coatings 2024, 14(8), 1049; https://doi.org/10.3390/coatings14081049
Submission received: 20 June 2024 / Revised: 16 July 2024 / Accepted: 12 August 2024 / Published: 16 August 2024
(This article belongs to the Special Issue The Present Status of Thermally Sprayed Composite Coatings)
Browse Figures
Versions Notes

Abstract

:
This work presents the results of research on the effect of a pulsed plasma treatment on the structure, phase composition, hardness, roughness, and elemental composition of Fe-TiB2-CrB2-based coatings. The Fe-TiB2-CrB2 coating was applied via the detonation method. Fe-TiB2-CrB2 powder mixtures were used for coating on AISI 1017 steel substrate with the coating surface being modified using a pulsed plasma treatment. The effects of the pulsed plasma treatment on the microstructure, phase composition, and mechanical properties of Fe-TiB2-CrB2 detonation coatings were investigated using an optical microscope, X-ray diffraction (XRD), scanning electron microscopy (SEM), a nanohardness tester, and a Leica 3D profilometer. The mechanical test results showed that the hardness of the Fe-TiB2-CrB2 coating increased from 8.22 Gpa to 15.6 GPa after the pulsed plasma treatment. The results of the tribological tests show that after the pulsed plasma treatment of Fe-TiB2-CrB2 coatings, a wear-resistant modified layer consisting of (Ti,Cr)B2 and alpha-Fe formed on its surface. It is determined that the surface modified coating layer has a low porosity compared to the coating base. In addition, it is determined that after the pulsed plasma treatment, a decrease in the average pore size is observed in the subsurface layer of the coating. The pulsed plasma treatment resulted in a decrease in the roughness parameter (Ra) from 12.2 μm to 6.6 μm, which is due to the melting of protruding particles.

1. Introduction

Iron-based coatings have become widespread and developed. They have excellent characteristics, such as high hardness and strength, low cost, and easy treatments [1]. In the last few years, the industry has shown increased interest in iron-based coatings due to the high cost and toxicity of Co- and Ni-based coatings and the need to add a binder phase for stability. There is particular interest in iron-based coatings with refractory crystals of embedding phases—(Ti,Cr)B2—which have high performance characteristics.
Thermal spraying is considered the most practical method for applying protective iron-based coatings. In thermal spraying, thermal and kinetic energy is used to accelerate the initial powder and it is sprayed onto the substrate. Thermal spraying involves the use of many methods, such as air plasma spraying (APS) [2,3], high-velocity oxygen spraying (HVOF) [4,5], arc spraying (AS) [6,7], vacuum plasma spraying (VPS) [8,9], cold spraying [10,11], and detonation spraying (DS) [12,13]. These methods differ in terms of heat source, the shape of the coating material, and the rate at which the material is applied, resulting in a range of coating properties and applications.
Among the various thermal spraying methods, DS has several advantages due to its simplicity and its ability to produce coatings with high bond strength, wear resistance, hardness, and density [14,15,16,17]. The high particle velocities achieved via detonation spraying (up to 1200 m/s) ensure the strong adhesion of the coating to the substrate. In addition, the process allows precise control of the coating properties and minimal oxidation due to rapid heating and cooling cycles. However, the major disadvantages of thermal coatings, including detonation coatings, involve porosity, roughness, and relatively poor hardness and corrosion resistance. In addition, in thermal spraying, there is a high density of defects (cracks and pores), the presence of unmelted particles, and greater heterogeneity of the deposited phases. In most cases, an additional post-deposition thermal treatment is required to eliminate metallurgical defects, reduce porosity, and improve inter-plate adhesion as well as adhesion between the coating and the substrate [18]. After the heat treatment, it is usually possible to obtain a dense coating with high cohesive and adhesion strength [19]. Generally, conventional heat treatment methods often lead to additional oxidation of the coating due to the low heating rate, which negatively affects the performance of the material [20,21]. Therefore, in the era of globalization, product competitiveness is achieved by improving manufacturing processes and developing non-traditional, high-performance surface treatment processes. These include technologies that utilize a concentrated energy flow. One of these technologies is the pulsed plasma treatment. This method involves surface modification using a magnetic field, electric current (or a stream of charged particle flux), and a high-gradient heat flux (plasma) that contains both non-metallic and metallic alloying elements. Pulsed plasma treatment (PPT) provides fast heating (heating time 10−3~10−4 s) of the surface layer followed by intensive cooling of it by heat dissipation into the product volume. The high-speed (up to 107 K/s) melting and crystallization of surface layers contribute to the formation of a nanodisperse crystal structure and high density of dislocations.
Combined technology, including coating deposition followed by a pulsed plasma treatment, makes it possible, in many cases, to achieve an additional increase in the physical, mechanical, and tribological properties of the material [22,23].
Pogrebnyak et al. [24,25] investigated surface modification via exposure to a pulsed plasma jet having high velocities of up to 107 K/s and a high temperature in the jet. The results demonstrate that surface modification via pulsed plasma flow significantly improves mechanical properties, such as service resistance, hardness, corrosion and abrasion resistance, etc. Tyurin et al. [26,27] conducted studies where they treated the surface of metal–ceramic detonation coatings with a pulsed plasma stream. We have carried out studies on pulsed plasma surface modifications of Cr3C2-NiCr, Al2O3-NiCr, and Ni-Cr-Al coatings [28,29,30]. According to the obtained data, it is possible to say that the modification of coatings using a pulsed plasma flow leads to increased tribological and mechanical properties in comparison with samples not subjected to a pulsed plasma treatment.
Nevertheless, most previous works were limited to the study of metal–ceramic coatings. To date, there are many publications on the preparation of iron-based coatings using various methods, but there is still a lack of work on the effects of pulsed plasma treatments on the structure and properties of iron-based coatings. In the work by Kengesbekov, A. B. et al. [30] the influence of pulsed plasma treatment on the properties of iron-based coatings was investigated, where it is possible to observe the improvement of coating properties with increasing distance. But in the paper little research was described, i.e., there was no comprehensive study (tribological properties, morphology, erosion resistance, abrasive wear), as well as a further increase in the distance.
In this study, the effects of pulsed plasma surface modification on the properties of Fe-TiB2-CrB2 coatings are investigated.

2. Materials and Methods

2.1. Materials

In this study, protective coatings made of eutectic alloy powder containing iron, titanium, and chromium diborides were obtained and analyzed. Table 1 shows the chemical composition of the powder. We used powder with a particle size of less than 60 microns and a spherical shape (Figure 1). As a substrate, we used samples from structural steel 3 (AISI 1017) with a thickness of 5 mm. Table 2 shows the chemical composition of the substrate.

2.2. Methods

2.2.1. Detonation Spraying

The coating application is performed using a multi-chamber detonation unit (MCDU) (Figure 2) [31,32]. The detonation products of combustion of a flammable gas mixture (propane–butane, oxygen, air) heat and accelerate the powder material during the coating application process.
The multi-chamber detonation unit (MCDU) offers several advantages. By varying the ratio of gases in the explosive mixture, the temperature of the combustion products can be adjusted over a wide range. Using multiple combustion chambers allows the formation of a system of waves consisting of detonation and shock waves. This enables the achievement of high velocity (up to 1000 m/s) of the sprayed powder by redistributing detonation energy between the kinetic and thermal energy of combustion products. This high velocity results in the formation of a coating with low porosity and high adhesion to the substrate. The process’s cyclic nature and the pulse’s short duration prevent overheating of the sample. In this particular case, coatings were obtained at a distance of 50 mm, with 4 passes made. The length of the nozzle for heating and acceleration of the powder is 300 mm, diameter is 16 mm. The speed of movement of the sample surface relative to the MCDU was 2000 mm/min. The coating was formed directly on the surface of the sample, without applying an intermediate layer. The composition of the combustible gas mixture is shown in Table 3.

2.2.2. Pulsed Plasma Treatment

After obtaining the coatings, the samples were treated with pulsed plasma flow at the Impulse-6 installation (Figure 3). During pulsed plasma treatment, the material undergoes a complex impact, including shock, electromagnetic, and thermal effects. Each of these plays a role in initiating diffusion processes during surface modification. [33,34]. This allows for the generation of pulsed plasma at frequencies starting from 1.2 Hz and energy up to 7 kJ. The surface is subsequently subjected to repeated pulsed heat exposure with heat flux capacities of approximately 104~106 W/cm2. During pulsed plasma treatment, the surface layer is rapidly heated (within 10−3~10−4 s) and then intensively cooled by heat transfer to the bulk of the material. Crystallization and melting of surface layers at a rate of up to 107 K/s led to the formation of a fine-grained crystal structure and increased dislocation density. Electromagnetic effects caused by current flow (10 kA/cm2) in combination with pulsed thermal effects on surface layers accelerate various physical and chemical processes. In high-resistance coating areas, the pulsed electric current releases thermal energy. This causes them to heat up to the melting point and activates the diffusion process and ultimately “heals” defects such as microcracks and pores, thereby improving adhesion properties with the appropriate treatment parameters. Table 4 shows the parameters of pulsed plasma treatment.

2.2.3. X-ray Diffraction Analysis

X-ray phase analysis of detonation coatings before and after pulsed plasma treatment was conducted using an X’PertPRO X-ray diffractometer (Philips Corporation, Amsterdam, the Netherlands), at 40 kV and 30 mA with Cu-Kα radiation (λ = 1.5418 Å). Measurements were performed in the 2θ range of 20°–90° with a step size of 0.05 and a counting time of 1 s/step. The diffractograms were analyzed using the HighScore program.

2.2.4. Surface Morphology Analysis

Surface morphology was studied using a TESCAN MIRA3 LMH scanning electron microscope (SEM) (TESCAN, Brno, Czech Republic). Microimages of the coating surface were obtained using an Altami MET 5S metallographic microscope (Altami LLC, St. Petersburg, Russia).

2.2.5. Roughness and Wear Volume

Roughness and wear volume were evaluated using a non-contact profilometer, Leica DCM8 (Leica Microsystems, Wetzlar, Germany). The confocal method was used for roughness measurement, employing a Leica EPI 20× objective and Leica Scan 6.5 software. The obtained data were processed using the Mountains program.

2.2.6. Hardness Test

To measure the hardness of samples before and after pulsed plasma treatment, we used a NanoScan-4D nanohardness tester (FGBU “TISNUM”, Moscow, Russia) according to GOST R8.748-2011. A Berkovich indenter was used and measurements were carried out at a load of 100 mN and 20 indentations.

2.2.7. Tribological Test

Tribological friction tests were carried out under reciprocating motion with a fixed load [35]. A silicon carbide (SiC) ball with a diameter of 3.969 mm and a hardness of HV = 2800 was used for the tests and was pressed against the specimen surface using weights to apply force FN. The system that moved the plate included two trolleys with bearings moving in the same direction, which allowed the friction force to be evenly distributed. The drive consisted of an electric mechanism, which included a stepper motor and helical gear. The traveling force was transmitted from the larger carriage to the smaller one via a strain gauge. This system provided a constant motion of the steel plate relative to the ball with a given velocity Vs and displacement S. The force causing the movement FT was recorded at a frequency of 10 Hz [35]. In each stage of the three measurements, a steel plate mounted on a moving carriage performed a series of 500 motion cycles. Each cycle included two movements in opposite directions at a maximum velocity of Vsmax = 5 mm/s. The time for each directional moverment was 0.4 s, and the load on the friction unit was FN = 20 N. The tests were carried out under technically dry friction conditions. The coefficient of friction μ was determined from the average friction force FT. Wear was measured as the average width of the wear track on the steel specimen using a microscope after the completion of the tests.

2.2.8. Abrasion Tests

The abrasive wear test was carried out on an experimental unit according to GOST 23.208-79 [36], which is analogous to the American standard ASTM G65 [37]. Specifically, the tests were conducted using the “rotating roller—flat surface” method.
Erosion resistance tests were conducted using a special apparatus in accordance with ASTM G76-18 [38]. The test was performed at room temperature using a tube with a 3 mm diameter nozzle, at a distance of 10 mm from the specimen and at an angle of 90° to its surface. Quartz sand with a grain size of 50 µm was used as an abrasive material. The test duration was 5 min for each specimen.

3. Results and Discussion

3.1. Roughness

The results of measuring the surface roughness of Fe-TiB2-CrB2 coatings and the obtained profilograms are presented in Figure 4. The surface of coatings is characterized by an inhomogeneous structure. The parameter of surface roughness evaluation of Fe-TiB2-CrB2 coatings was Ra. Ra represents the arithmetic mean deviation of the profile. The roughness of the coatings before processing had Ra = 12.2 μm (Figure 4a). The results of roughness measurement after plasma treatment showed a significant reduction: for the coating with a surface distance of 50 mm—Ra = 6.6 µm, 60 mm—Ra = 7.2 µm, 70 mm—Ra = 11.3 µm. The reduction in roughness by approximately ≈ 48% at distances of 50 mm and 60 mm (Figure 4b,c), compared to the roughness parameters before processing, is explained by melting of protruding fragments and pores by the pulsed plasma flow, which led to a decrease in surface roughness. It is also shown that as the distance of pulsed plasma processing increases, the reduction in roughness decreases (Figure 4d).

3.2. X-ray Diffraction Analysis

Figure 5 shows the X-ray diffraction analysis of the coating surface before and after pulsed plasma treatment. The figure shows that after PPT, new reflexes of CrB2 and TiB2 phases are observed on the diffractogram of Fe-TiB2-CrB2 coatings. The change in the fraction of (Ti,Cr)B2 phase indicates solid-phase transformation during pulsed plasma activation, associated with heating above the melting point and cooling of the samples during processing. In our case, this phase is the (Ti,Cr)B2 embedding phase, which forms the hardening framework and bears the main load [39,40]. The metallic component is a main phase, it fills the space between the individual crystals of the embedding phase. According to the theory of eutectic crystallization [40,41], each eutectic alloy (let us take a two-component alloy system as an example) has three types of structure, which correspond to three crystallization mechanisms. At low cooling rates, the formation and growth of phases constituting the eutectic alloy occur independently of each other, resulting in the formation of a structure with large crystals. In a wide range of cooling rates, exceeding the first case, and with the limitation of diffusive mobility of atoms in front of the crystallization front, the crystallization mechanism changes. In the supercooled liquid, crystals of the phase that nucleates and, subsequently, leads to eutectic crystallization are the first to precipitate. This phase, know as the nucleating and leading phase, forms a highly branched single crystal within the eutectic colony.

3.3. Tribological Test

By analyzing Figure 6, which includes 3D scans, cross-sectional profiles, and depth and width of wear marks, it can be seen that the coating without PPT has the worst wear kinetics (it has the largest depth and width of marks). The coating after PPT shows increased wear resistance compared to the one without PPT. The sample machined at 60 mm (Figure 6c) has the highest wear resistance (it has the smallest depth and width of marks). According to the XRD analysis, this is most likely due to the increased proportion of (Ti,Cr)B2 phase, which is characterized by high wear resistance.
Figure 7 shows the results for the wear volume and friction coefficient of the coating during reciprocating motion. The results indicate that in the initial sample (before machining), the average friction coefficient of the coatings is ~0.54 and, after PPT, the friction coefficient decreases to is 0.41 (50 mm), 0.47 (60 mm), and 0.52 (70 mm), depending on the machining distance. At a distance of 50 mm, the surface has less roughness, which is due to the melting of the surface, helping to reduce the coefficient of friction. When the surface is melted, its microrelief becomes smoother, reducing the mechanical resistance to sliding and thus the coefficient of friction. As shown in the preceding figure (Figure 6), the sample treated at 60 mm has a decreased track width and has the lowest wear volume (Figure 7) relative to other treatment distances, indicating significantly improved wear resistance. The test results show that after PPT the coating’s wear resistance has increased, which, according to the XRD analysis, is most likely due to the increased proportion of phases (appearance of new phase reflexes (Ti,Cr)B2) characterized by high wear resistance. The test results show that at a distance of 70 mm pulsed plasma treatment results in a decrease in wear resistance. This phenomenon may be due to the lower degree of exposure to pulsed plasma.

3.4. Morphology Analysis

Images of the cross-section of the coating material before and after pulsed plasma treatment are presented in Figure 8. According to the results obtained from SEM imaging, the sample before pulsed plasma treatment (Figure 8a) has a structure characteristic of detonation spraying, with large open defects of medium size. After treatment, the boundaries of large defects merge in the near-surface layer of the coating (marked by white arrows in the enlarged sections) and pores decrease to minimal values, which is explained by the pulsed plasma effect. The boundary between the coating (circled in red) and the substrate is free of defects only at a processing distance of 60 mm (Figure 8c), which is due to the use of high-energy coating sputtering technology and the subsequent elimination of defects during the passage of electrical pulses. As the distance increases (Figure 8d), a decrease in defect melting and healing is observed in the subsurface layer of the coating. Reducing the processing distance to 50 mm leads to peeling of the coating from the substrate (Figure 8b).

3.5. Hardness Test

The results of hardness measurements of Fe-TiB2-CrB2 coatings before and after PPT are presented in Figure 9. Figure 9 shows that the microhardness of the surface after PPT, as well as the microhardness of the near-surface layers of the coatings, is higher compared to the untreated coating. The thickness of the hardened layer (modified by the PPT method) is 20–30 µm. Beyond this layer, the microhardness decreases to 8.7 GPa and remains at the same level as the microhardness of coatings before PPT (in the initial state). The highest hardness was observed after pulsed plasma treatment at a distance of 60 mm and was about 15.6 GPa. As the distance between the plasma gun and the treated surface increased to 70mm, the hardness gradually decreased. This phenomenon may be due to the varying degrees of local melting of the material, which depend on the distance of exposure to the pulsed plasma.

3.6. Abrasion and Erosion Wear

Abrasive wear is a key factor that limits the service life of most machine and equipment components used in various industries. To evaluate the wear resistance of Fe-TiB2-CrB2 coatings before and after pulsed plasma treatment (PPT), tests were performed on a specialized bench. Resistance to erosion and abrasive wear was assessed by mass loss, i.e., by measuring the mass of the specimens before and after the test. During each test, the mass loss of the samples was measured, and then the mean values and standard deviations were calculated. The results of these tests are presented in Table 5. Analysis of the test results of wear resistance of coatings to abrasive wear showed that coatings after modification by plasma treatment have the highest resistance to wear compared to the original sample (before treatment). The results of these tests showed that the weight loss after pulsed plasma treatment was less (50 mm—0.0122 g.; 60 mm—0.0102 g.; 70 mm—0.0197 g.) compared to the untreated specimen (initial—0.0230 g.). This indicates a significant improvement in the abrasion resistance of the material. This improvement can be explained by the increase in the content of hardening phases (Ti,Cr)B2 and alpha-Fe in the coating after PPT.
Erosion wear test results are also given in Table 5. The erosion wear test results showed that the weight loss after pulsed plasma treatment was less (50 mm—0.1456 g.; 60 mm—0.1123 g.; 70 mm—0.1877 g.) compared to the untreated sample (initial—0.0211 g.). These tests confirmed that the Fe-TiB2-CrB2 coatings that underwent PPT show significantly improved resistance to erosion. This improvement can be attributed to the increased content of (Ti,Cr)B2 and alpha-Fe phases in the coating after PPT.
Table 6 presents the results of the correlation analysis. According to the analysis, the distance of 60 mm is optimal, as the coating treated at 60 mm has better results compared to the other samples.

4. Conclusions

Based on the evaluation and analysis of all the results obtained, the following main conclusions can be drawn from the present research work:
After pulsed plasma treatment, new phase reflexes of (Ti,Cr)B2 are found on the diffraction pattern, which has high wear resistance. In addition, the intensity of α-Fe peaks increased. Pulsed plasma treatment (PPT) contributes to the reduction of the surface roughness value and coating friction coefficient by ~2 times, increasing the hardness of the near-surface layer of Fe-TiB2-CrB2 coatings from ~8.8 GPa (initial) to ~15.6 GPa and wear resistance by a factor of 2 compared to the untreated coating. Pulsed plasma treatment significantly improves the resistance of Fe-TiB2-CrB2 coatings to both abrasive wear and erosion. After pulsed plasma treatment in the subsurface layer of the coating there is a reduction of pores to minimum values, which is due to the melting of the boundary of large defects. Pulsed plasma treatment of detonation coatings provides, in optimal modes, the formation of high-quality coatings from the eutectic alloy system Fe-TiB2-CrB2, including an increase in strength properties and hardness of the matrix without significant degradation and high values of localized defects.
According to the results of the research, the optimal mode of pulsed plasma treatment was selected, which improves the characteristics of detonation coatings of eutectic Fe-TiB2-CrB2 alloy.
This combined coating method, including detonation spraying of eutectic Fe-TiB2-CrB2 alloy coatings and subsequent pulsed plasma treatment, can be considered optimal for protecting the surfaces of parts operating under extreme conditions.

Author Contributions

B.R. and D.K. designed the experiments; D.K. and A.K. performed the experiments; A.S. and N.M. analyzed the data; B.R., D.K., A.S., A.K. and N.M. wrote, reviewed, and edited the paper. All authors have read and agreed to the published version of the manuscript.

Funding

This research has been funded by the Science Committee of the Ministry of Science and Higher Education of the Republic of Kazakhstan (Grant No. AP14871373).

Institutional Review Board Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

Data are contained within the article.

Conflicts of Interest

The authors declare that there are no conflicts of interest regarding the publication of this manuscript.

References

  1. Iqbal, A.; Siddique, S.; Maqsood, M.; Atiq Ur Rehman, M.; Yasir, M. Comparative analysis on the structure and properties of iron-based amorphous coating sprayed with the thermal spraying techniques. Coatings 2020, 10, 1006. [Google Scholar] [CrossRef]
  2. Wang, K.; Zhu, J.; Wang, H.; Yang, K.; Zhu, Y.; Qing, Y.; He, J. Air plasma-sprayed high-entropy (Y0.2Yb0.2Lu0.2Eu0.2Er0.2)3Al5O12 coating with high thermal protection performance. J. Adv. Ceram. 2022, 11, 1571–1582. [Google Scholar] [CrossRef]
  3. Chen, W.R.; Wu, X.; Marple, B.R.; Lima, R.S.; Patnaik, P.C. Pre-oxidation and TGO growth behaviour of an air-plasma-sprayed thermal barrier coating. Surf. Coat. Technol. 2008, 202, 3787–3796. [Google Scholar] [CrossRef]
  4. Rakhadilov, B.; Muktanova, N.; Kakimzhanov, D.; Adilkanova, M.; Kurbanbekov, S.; Abdulina, S. Influence of Varying the Spraying Distance on the Structural-Phase State and Mechanotribological Properties of 86WC-10Co-4Cr-Based Coatings Obtained by the HVOF Method. Coatings 2024, 14, 264. [Google Scholar] [CrossRef]
  5. Mittal, G.; Paul, S. Suspension and solution precursor plasma and HVOF spray: A review. J. Therm. Spray Technol. 2022, 31, 1443–1475. [Google Scholar] [CrossRef]
  6. Liang, D.; Zhou, Y.; Liu, X.; Zhou, Q.; Huang, B.; Zhang, E.; Shen, J. Wettability and corrosion performance of arc-sprayed Fe-based amorphous coatings. Surf. Coat. Technol. 2022, 433, 128129. [Google Scholar] [CrossRef]
  7. Ndumia, J.N.; Kang, M.; Gbenontin, B.V.; Lin, J.; Nyambura, S.M. A review on the wear, corrosion and high-temperature resistant properties of wire arc-sprayed Fe-based coatings. Nanomaterials 2021, 11, 2527. [Google Scholar] [CrossRef] [PubMed]
  8. Kim, H.S.; Kang, B.R.; Choi, S.M. Fabrication and characteristics of a HfC/TiC multilayer coating by a vacuum plasma spray process to protect C/C composites against oxidation. Corros. Sci. 2021, 178, 109068. [Google Scholar] [CrossRef]
  9. Smyrnova, K.V.; Bondar, O.V.; Borba-Pogrebnjak, S.O.; Kravchenko, Y.O.; Beresnev, V.M.; Zhollybekov, B.; Baimoldanova, L. The microstructure and mechanical properties of (TiAlSiY) N nanostructured coatings. In Proceedings of the 2017 IEEE 7th International Conference Nanomaterials: Application & Properties (NAP), Odessa, Ukraine, 10–15 September 2017; p. 01FNC13-1. [Google Scholar]
  10. Sun, W.; Chu, X.; Lan, H.; Huang, R.; Huang, J.; Xie, Y.; Huang, G. Current implementation status of cold spray technology: A short review. J. Therm. Spray Technol. 2022, 31, 848–865. [Google Scholar] [CrossRef]
  11. Winnicki, M.; Łatka, L.; Jasiorski, M.; Baszczuk, A. Mechanical properties of TiO2 coatings deposited by low pressure cold spraying. Surf. Coat. Technol. 2021, 405, 126516. [Google Scholar] [CrossRef]
  12. Ulianitsky, V.Y.; Batraev, I.S.; Rybin, D.K.; Dudina, D.V.; Shtertser, A.A.; Ukhina, A.V. Detonation Spraying of Cr3C2-NiCr Coatings and Their Properties. J. Therm. Spray Technol. 2022, 31, 598–608. [Google Scholar] [CrossRef]
  13. Kuchumova, I.D.; Batraev, I.S.; Cherkasova, N.Y.; Rybin, D.K.; Ukhina, A.V.; Botta, W.J.; Jorge, A.M., Jr. The influence of the O2/C2H2 ratio on the structure and properties of Fe66Cr10Nb5B19 detonation coatings. Mater. Today Proc. 2020, 25, 384–386. [Google Scholar] [CrossRef]
  14. Zhai, H.; Ou, M.; Cui, S.; Li, W.; Zhang, X.; Cheng, B.; Cai, A. Characterizations the deposition behavior and mechanical properties of detonation sprayed Fe-based amorphous coatings. J. Mater. Res. Technol. 2022, 18, 2506–2518. [Google Scholar] [CrossRef]
  15. Baizhan, D.; Sagdoldina, Z.; Buitkenov, D.; Kambarov, Y.; Nabioldina, A.; Zhumabekova, V.; Bektasova, G. Study of the Structural-Phase State of Hydroxyapatite Coatings Obtained by Detonation Spraying at Different O2/C2H2 Ratios. Crystals 2023, 13, 1564. [Google Scholar] [CrossRef]
  16. Rakhadilov, B.; Kakimzhanov, D.; Dautbekov, M.; Sagdoldina, Z.; Adylkanova, M.; Abylkalykova, R. Influence of Spraying Parameters on the Structure and Tribological Properties of Cr3C2-NiCr Detonation Coatings. Adv. Tribol. 2023, 2023, 6684656. [Google Scholar] [CrossRef]
  17. Kovaleva, M.G.; Goncharov, I.Y.; Novikov, V.Y.; Pavlenko, I.A.; Yapryntsev, M.N.; Vagina, O.N.; Kolisnichenko, O.V. Dense ZrB2-MoSi2 composite coating fabricated by a new multi-chamber detonation accelerator on carbon/carbon composites. Mater. Sci. Forum 2020, 987, 53–58. [Google Scholar] [CrossRef]
  18. Greenberg, J.B. Droplet size distribution effects in an edge flame with a fuel spray. Combust. Flame 2017, 179, 228–237. [Google Scholar] [CrossRef]
  19. Pengcheng, X.I.A.; Jingjiang, Y.U.; Xiaofeng, S.; Hengrong, G.; Zhuangqi, H.U. Influence of heat treatment on the microstructure and mechanical properties of DZ951 alloy. Rare Met. 2008, 27, 216–222. [Google Scholar]
  20. Trice, R.W.; Su, Y.J.; Mawdsley, J.R.; Faber, K.T.; De Arellano-Lopez, A.R.; Wang, H.; Porter, W.D. Effect of heat treatment on phase stability, microstructure, and thermal conductivity of plasma-sprayed YSZ. J. Mater. Sci. 2002, 37, 2359–2365. [Google Scholar] [CrossRef]
  21. Shieh, Y.H.; Wang, J.T.; Shih, H.C.; Wu, S.T. Alloying and post-heat-treatment of thermal-sprayed coatings of self-fluxing alloys. Surf. Coat. Technol. 1993, 58, 73–77. [Google Scholar] [CrossRef]
  22. Roata, I.C.; Croitoru, C.; Pascu, A.; Stanciu, E.M.; Hulka, I.; Petre, I.; Sbarcea, B.G. Surface engineering of Ni-Al coatings through concentrated solar heat treatment. Appl. Surf. Sci. 2020, 506, 144185. [Google Scholar] [CrossRef]
  23. Liu, L.; Xu, H.; Xiao, J.; Wei, X.; Zhang, G.; Zhang, C. Effect of heat treatment on structure and property evolutions of atmospheric plasma sprayed NiCrBSi coatings. Surf. Coat. Technol. 2017, 325, 548–554. [Google Scholar] [CrossRef]
  24. Pogrebnyak, A.D.; Tyurin, Y.N. Pulse-plasma modification of surface properties and coating. Usp. Fiz. Met. 2003, 4, 1–71. [Google Scholar] [CrossRef]
  25. Pogrebnjak, A.D.; Il’jashenko, M.; P Kul’ment’eva, O.; Kshnjakin, V.S.; Kobzev, A.P.; Tyurin, Y.N.; Kolisnichenko, O. Structure and properties of Al2O3 and Al2O3+ Cr2O3 coatings deposited to steel 3 (0.3 wt% C) substrate using pulsed detonation technology. Vacuum 2001, 62, 21–26. [Google Scholar] [CrossRef]
  26. Tyurin, Y.N.; Zgatkevich, M.L.; Pogrebnyak, A.D.; Kolisnichenko, O.V. Pulse plasma technology and equipment for surface modification. In Proceedings of the 4-th International Conference «Interaction of Radiation with Solids», Minsk, Belarus, 3–5 October 2001. [Google Scholar]
  27. Tyurin, Y.N.; Pogrebnyak, A.D.; Kolisnichenko, O.V. Intensification of interaction between plasma and surface by using electric current. In Proceedings of the 4-th International Conference «Interaction of Radiation with Solids», Minsk, Belarus, 3–5 October 2001. [Google Scholar]
  28. Rakhadilov, B.K.; Tyurin, Y.; Kakimzhanov, D.; Baizhan, D.; Kolisnichenko, O.; Zhurerova, L. Deposition of duplex Cr3C 2-NiCr coatings on steel using a combined technique of gas detonation spraying and pulse-plasma treatment. High Temp. Mater. Process. Int. Q. High-Technol. Plasma Process. 2021, 25, 25–37. [Google Scholar] [CrossRef]
  29. Kakimzhanov, D.; Rakhadilov, B.; Sulyubayeva, L.; Dautbekov, M. Influence of Pulse-Plasma Treatment Distance on Structure and Properties of Cr3C2-NiCr-Based Detonation Coatings. Coatings 2023, 13, 1824. [Google Scholar] [CrossRef]
  30. Kengesbekov, A.B.; Rakhadilov, B.K.; Tyurin, Y.N.; Magazov, N.M.; Kylyshkanov, M.K.; Sagdoldina, Z.B. The influence of pulse-plasma treatment on the phase composition and hardness of Fe-TiB2-CrB2 coatings. Eurasian J. Phys. Funct. Mater. 2021, 5, 155–162. [Google Scholar] [CrossRef]
  31. Sirota, V.; Pavlenko, V.; Cherkashina, N.; Kovaleva, M.; Tyurin, Y.; Kolisnichenko, O. Preparation of aluminum oxide coating on carbon/carbon composites using a new detonation sprayer. Int. J. Appl. Ceram. Technol. 2021, 18, 483–489. [Google Scholar] [CrossRef]
  32. Korzhyk, V.; Tyurin, Y.; Kolisnichenko, O. (Eds.) Theory and Practice of Plasma-Detonation Technology of Surface Hardening Metal Products; PC Technology Center: Kharkiv, Ukraine, 2021; p. 244. [Google Scholar]
  33. Zou, J.; Lu, L.; Kolisnichenko, O.V.; Chen, W.; Yu, J.M. Gas nitriding of a plasma detonation modified die steel. Mater. Lett. 2021, 287, 129297. [Google Scholar] [CrossRef]
  34. Kushnarova, O.; Berdnikova, O.; Tyurin, Y.; Kolisnichenko, O.; Alekseienko, T.; Titkov, Y. Peculiarities of the Surface Structure of High-Speed Steel After Pulse-Plasma Treatment. In Proceedings of the 2023 IEEE 13th International Conference Nanomaterials: Applications & Properties (NAP), Bratislava, Slovakia, 10–15 September 2023; p. IMT07-1. [Google Scholar]
  35. Łęcka, K.M.; Antończak, A.J.; Kowalewski, P.; Trzcinski, M. Wear resistance of laser-induced annealing of AISI 316 (EN 1.4401) stainless steel. Laser Phys. 2018, 28, 096005. [Google Scholar] [CrossRef]
  36. GOST 23.207-79; Ensuring of Wear Resistance of Products. Testing of Engineering Materials for Impact Abrasive Wear. 1979. Available online: http://vsegost.com/Catalog/43/4374.shtml (accessed on 31 August 2022).
  37. Doering, A.; Danks, D.; Mahmoud, S.; Scott, J. Evaluation of ASTM G65 abrasive—Spanning 13 years of sand. Wear 2011, 271, 1252–1257. [Google Scholar] [CrossRef]
  38. ASTM G76-18; Standard Test Method for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets. ASTM International: West Conshohocken, PE, USA, 2018.
  39. Panarin, V.E.; Tyurin, Y.N.; Kolisnichenko, O.V.; Shmatko, O.A.; Zakharov, S.M.; Svavilny, N.E. Zashchitnye pokrytiya iz evtekticheskogo splava na osnove zheleza s tugoplavkimi boridami. Aviac. Kosm. Tekhnika Tekhnologiya 2016, 6, 15–20. (In Russian) [Google Scholar]
  40. Panarin, V.E.; Zakharov, S.M.; Shmatko, O.A.; Kisel, V.M.; Terentyev, A.E. Plasma coating of eutectic alloy of the Fe-TiB2-CrB2 quasi-triple system. Aviac. Kosm. Tekhnika Tekhnologiya 2014, 8, 108–112. [Google Scholar]
  41. Kiryukhantsev-Korneev, P.V.; Sytchenko, A.D.; Sviridova, T.A.; Sidorenko, D.A.; Andreev, N.V.; Klechkovskaya, V.V.; Levashov, E.A. Effects of doping with Zr and Hf on the structure and properties of Mo-Si-B coatings obtained by magnetron sputtering of composite targets. Surf. Coat. Technol. 2022, 442, 128141. [Google Scholar] [CrossRef]
Coatings 14 01049 g001
Figure 1. Appearance of the initial Fe-TiB2-CrB2 powder.
Figure 1. Appearance of the initial Fe-TiB2-CrB2 powder.
Coatings 14 01049 g001
Coatings 14 01049 g002
Figure 2. Equipment for coating application using MKDU. (a)—scheme of the installation: device—1; powder feeder—2; gas supply console—3; control system—4; system for moving the detonation device—5; (b)—appearance of the installation during operation.
Figure 2. Equipment for coating application using MKDU. (a)—scheme of the installation: device—1; powder feeder—2; gas supply console—3; control system—4; system for moving the detonation device—5; (b)—appearance of the installation during operation.
Coatings 14 01049 g002
Coatings 14 01049 g003
Figure 3. General view (a) and schematic view (b) of the pulsed plasma installation [29]. 1—chamber of detonation, 2—power supply, 3, 4—coaxial electrodes, 5—eroded electrode, 6—plasma, 7—sample.
Figure 3. General view (a) and schematic view (b) of the pulsed plasma installation [29]. 1—chamber of detonation, 2—power supply, 3, 4—coaxial electrodes, 5—eroded electrode, 6—plasma, 7—sample.
Coatings 14 01049 g003
Coatings 14 01049 g004
Figure 4. Results of roughness measurement and 3D surface image of Fe-TiB2-CrB2 coatings before (a) and after plasma treatment ((b)—50 mm, (c)—60 mm, (d)—70 mm).
Figure 4. Results of roughness measurement and 3D surface image of Fe-TiB2-CrB2 coatings before (a) and after plasma treatment ((b)—50 mm, (c)—60 mm, (d)—70 mm).
Coatings 14 01049 g004
Coatings 14 01049 g005
Figure 5. X-ray diffraction diagrams of Fe-TiB2-CrB2 coatings before (a) and after plasma treatment ((b)—60 mm, (c)—50 mm, (d)—70 mm).
Figure 5. X-ray diffraction diagrams of Fe-TiB2-CrB2 coatings before (a) and after plasma treatment ((b)—60 mm, (c)—50 mm, (d)—70 mm).
Coatings 14 01049 g005
Coatings 14 01049 g006
Figure 6. Three-dimensional scans, cross-section profiles and depth and width of wear marks before (a) and after pulsed plasma treatment ((b)—50 mm, (c)—60 mm, (d)—70 mm).
Figure 6. Three-dimensional scans, cross-section profiles and depth and width of wear marks before (a) and after pulsed plasma treatment ((b)—50 mm, (c)—60 mm, (d)—70 mm).
Coatings 14 01049 g006
Coatings 14 01049 g007
Figure 7. Tribological test results.
Figure 7. Tribological test results.
Coatings 14 01049 g007
Coatings 14 01049 g008
Figure 8. Structure of Fe-TiB2-CrB2 coating material before (a) and after pulsed plasma treatment ((b)—50 mm, (c)—60 mm, (d)—70 mm).
Figure 8. Structure of Fe-TiB2-CrB2 coating material before (a) and after pulsed plasma treatment ((b)—50 mm, (c)—60 mm, (d)—70 mm).
Coatings 14 01049 g008
Coatings 14 01049 g009
Figure 9. Graph of hardness distribution by depth of Fe-TiB2-CrB2 coatings before and after pulsed plasma treatment.
Figure 9. Graph of hardness distribution by depth of Fe-TiB2-CrB2 coatings before and after pulsed plasma treatment.
Coatings 14 01049 g009
Table 1. Composition of Fe-TiB2-CrB2 powder (wt.%).
Table 1. Composition of Fe-TiB2-CrB2 powder (wt.%).
FeNi, %Cr, %Ti, %B, %Al, %
base6 ÷ 820.0 ÷ 20.52.4 ÷ 2.52.5 ÷ 2.65.6
Table 2. Chemical composition of steel 3 (AISI 1017) (wt.%).
Table 2. Chemical composition of steel 3 (AISI 1017) (wt.%).
CSiMnNiSPCrNCuAsFe
0.14 ÷ 0.220.15 ÷ 0.30.4 ÷ 0.65<0.3<0.5<0.04<0.3<0.008<0.3<0.08base
Table 3. Gas composition.
Table 3. Gas composition.
ChamberGas Mixture ComponentsFlow Rate, m3/h
1 chamberO23.3
air1.1
C3H8 + C4H100.7
2 chambersO23
air1
C3H8 + C4H100.67
Table 4. Parameters of pulsed plasma treatment.
Table 4. Parameters of pulsed plasma treatment.
ParametersValue
Voltage across the capacitor bank (V)3200
Capacitance of the discharge circuit capacitor bank (µF)960
Inductance of the discharge circuit (µH)30
Plasma pulse rate (Hz)1.2
Speed of plasma torch movement relative to the product (mm/s)3.4
Processing distance (mm)50, 60, 70
Table 5. Erosion and abrasion wear results.
Table 5. Erosion and abrasion wear results.
№CoatingsAbrasive Wear, Mass Loss (g)Erosive Wear, Mass Loss (g)
1Fe-TiB2-CrB2 (initial, without PPT)0.02300.2311
2Fe-TiB2-CrB2 (50 mm, after PPT)0.01220.1456
3Fe-TiB2-CrB2 (60 mm, after PPT)0.01020.1123
4Fe-TiB2-CrB2 (70 mm, after PPT)0.01970.1877
Table 6. Correlative results of the research.
Table 6. Correlative results of the research.
SampleRoughness, Ra, μmFriction CoefficientWear Volume, mm3Hardness, GPaAbrasive Wear, Mass Loss (g)Erosive Wear, Mass Loss (g)
1Fe-TiB2-CrB2 (initial, without PPT)12.20.540.398.30.02300.2311
2Fe-TiB2-CrB2 (50 mm, after PPT)6.60.410.2114.10.01220.1456
3Fe-TiB2-CrB2 (60 mm, after PPT)7.20.470.1815.60.01020.1123
4Fe-TiB2-CrB2 (70 mm, after PPT)11.30.520.379.80.01970.1877
Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to people or property resulting from any ideas, methods, instructions or products referred to in the content.

Share and Cite

MDPI and ACS Style

Rakhadilov, B.; Kakimzhanov, D.; Seitkhanova, A.; Kengesbekov, A.; Muktanova, N. The Influence of Distance Pulsed Plasma Treatment on the Structure and Properties of Detonation Coatings from Eutectic Alloy Fe-TiB2-CrB2. Coatings 2024, 14, 1049. https://doi.org/10.3390/coatings14081049

AMA Style

Rakhadilov B, Kakimzhanov D, Seitkhanova A, Kengesbekov A, Muktanova N. The Influence of Distance Pulsed Plasma Treatment on the Structure and Properties of Detonation Coatings from Eutectic Alloy Fe-TiB2-CrB2. Coatings. 2024; 14(8):1049. https://doi.org/10.3390/coatings14081049

Chicago/Turabian Style

Rakhadilov, Bauyrzhan, Dauir Kakimzhanov, Ainur Seitkhanova, Aidar Kengesbekov, and Nazerke Muktanova. 2024. "The Influence of Distance Pulsed Plasma Treatment on the Structure and Properties of Detonation Coatings from Eutectic Alloy Fe-TiB2-CrB2" Coatings 14, no. 8: 1049. https://doi.org/10.3390/coatings14081049

Note that from the first issue of 2016, this journal uses article numbers instead of page numbers. See further details here.

Article Metrics

Back to TopTop