Search Results (5)

A Ni-based powder composed of NiSiB + 60% WC was deposited onto a structural-steel substrate using two methods: laser cladding (LC) and plasma powder transferred arc welding (PPTAW). The resulting surface layers were analyzed and compared. Both methods resulted in the precipitation of secondary WC phases in the solidified matrix, but the PPTAW clad exhibited a dendritic microstructure. The microhardness of the clads prepared by both methods was similar, but the PPTAW clad showed higher resistance to abrasive wear compared to the LC clad. The thickness of the transition zone (TZ) was thin for both methods, with a coarse-grain heat-affected zone (CGHAZ) and peninsula-like macrosegregations observed in clads from both methods. The PPTAW clad showed a unique cellular–dendritic growth solidification (CDGS) and a type-II boundary at the TZ attributed to its thermal cycles. While both methods resulted in metallurgical bonding of the clad to the substrate, the LC method exhibited a lower dilution coefficient. The LC method also resulted in a larger HAZ with higher hardness compared to the HAZ of the PPTAW clad. The findings of this study indicate that both methods are promising for antiwear applications due to their wear-resistant properties and metallurgical bonding to the substrate. The PPTAW clad may be particularly useful in applications that require higher resistance to abrasive wear, while the LC method may be advantageous in applications that require lower dilution and larger HAZ. Full article

Increasing demand for sustainable approaches to mining and raw material extraction, has prompted the need to explore advanced methods of surface modification for structural steels used in the extractive industry. The technology of powder plasma transferred arc welding (PPTAW), was used in this study as a surface modification technique to improve upon the abrasive wear resistance of structural steel grade EN S355. PPTAW process parameters, namely, plasma transferred arc (PTA) current and plasma gas flow rate (PGFR), were varied, and the effects of the variation were studied and used as criteria for selecting optimum conditions for further studies and parametric reproducibility. Two metal matrix composite (MMC) powders were used in the process, having compositions of Ni-Si-B+60 wt%WC (PG) and Ni-Cr-Si-B+45 wt%WC (PE). Microstructural observation under a scanning electron microscope (SEM) revealed a dendritic, multi-directional microstructure consisting of partially dissolved primary tungsten carbide particles and secondary tungsten carbide precipitates within the MMC solid solution. The hardness of the surface layers was higher than that of a reference AR400 steel by more than 263 HV. Final surface layers obtained from the MMC powders had abrasive wear resistance up to 5.7 times that of abrasion-resistant reference AR400 steel. Alloying the MMC matrix with chromium increased the hardness by 29.4%. Under the same process conditions, MMC powder with 60 wt% WC reinforcement had better abrasive wear resistance by up to 45.8% more than the MMC powder with 45 wt% WC. Full article

This article is the last of a series of publications included in the MDPI special edition entitled “Innovative Technologies and Materials for the Production of Mechanical, Thermal and Corrosion Wear-Resistant Surface Layers and Coatings”. Powder plasma-transferred arc welding (PPTAW) was used to surface metal matrix composite (MMC) layers using a mixture of cobalt (Co3) and nickel (Ni3) alloy powders. These powders contained different proportions and types of hard reinforcing phases in the form of ceramic carbides (TiC and WC-W₂C), titanium diboride (TiB₂), and of tungsten-coated synthetic polycrystalline diamond (PD-W). The resistance of the composite layers to cracking under the influence of dynamic loading was determined using Charpy hammer impact tests. The results showed that the various interactions between the ceramic particles and the metal matrix significantly affected the formation process and porosity of the composite surfacing welds on the AISI 4715 low-alloy structural steel substrate. They also affected the distribution and proportion of reinforcing-phase particles in the matrix. The size, shape, and type of the ceramic reinforcement particles and the surfacing weld density significantly impacted the brittleness of the padded MMC layer. The fracture toughness increased upon decreasing the particle size of the hard reinforcing phase in the nickel alloy matrix and upon increasing the composite density. The calculated mean critical stress intensity factor K_Ic of the steel samples with deposited layers of cobalt alloy reinforced with TiC and PD-W particles was 4.3 MPa⋅${\mathrm{m}}^{\frac{1}{2}}$ higher than that of the nickel alloy reinforced with TiC and WC-W₂C particles. Full article

The article is the continuation of a cycle of works published in a Special Issue of MDPI entitled “Innovative Technologies and Materials for the Production of Mechanical, Thermal and Corrosion Wear-Resistant Surface Layers and Coatings” related to tests concerning the microstructure and mechanical properties of innovative surface layers made using the Powder Plasma Transferred Arc Welding (PPTAW) method and intended for work surfaces of drilling tools and machinery applied in the extraction industry. A layer subjected to tests was a metal matrix composite, made using powder based on a nickel alloy containing spherical fused tungsten carbide (SFTC) particles, which are fused tungsten carbide (FTC) particles and spherical particles of tungsten-coated synthetic metal–diamond composite (PD-W). The layer was deposited on the substrate of low-alloy structural steel grade AISI 4715. The results showed that the chemical composition of the metallic powder as well as the content of the hard phase constituting the matrix enabled the making of a powder filler material characterised by very good weldability and appropriate melting. It was also found that the structure of the Ni-WC-PD-W layer was complex and that proper claddings (characterised by the uniform distribution of tungsten carbide (WC)) were formed in relation to specific cladding process parameters. In addition, the structure of the composite layer revealed the partial thermal and structural decomposition of tungsten carbide, while the particles of the synthetic metal–diamond composite remained coherent. The deposited surface layer was characterised by favourable resistance to moderate dynamic impact loads with a potential energy of 200 J, yet at the same time, by over 12 times lower metal–mineral abrasive wear resistance than the previously tested surface layer made of cobalt-based composite powder, the matrix of which contained the hard phase composed of TiC particles and synthetic metal–diamond composite. The lower abrasive wear resistance could result from a different mechanism responsible for the hardening of the spherical particles of the hard phase susceptible to separation from the metal matrix, as well as from a different mechanism of tribological wear. Full article

The article discusses test results concerning an innovative surface layer obtained using the cladding with powder plasma transferred arc welding (PPTAW) method. The above-named layer, being a metal matrix composite (MCM), is characterised by high abrasive wear resistance, resistance to pressure and impact loads, and the possibility of operation at elevated temperatures. The layer was made using powder in the form of a cobalt alloy-based composite reinforced with monocarbide TiC particles and superhard spherical particles of synthetic metal–diamond composite provided with tungsten coating. The surface layer was deposited on a sheet made of low-alloy structural steel grade AISI 4715. The layer is intended for surfaces of inserts of drilling tools used in the extraction industry. The results showed the lack of the thermal and structural decomposition of the hard layer reinforcing the matrix during the cladding process, its very high resistance to metal-mineral abrasive wear and its resistance to moderate impact loads. The abrasive wear resistance of the deposited layer with particles of TiC and synthetic metal–diamond composite was about than 140 times higher than the abrasive wear resistance of abrasion resistant heat-treated steel having a nominal hardness of 400 HBW. The use of diamond as a metal matrix reinforcement in order to increase the abrasive resistance of the PPTAW overlay layer is a new and innovative area of inquiry. There is no information related to tests concerning metal matrix surface layers reinforced with synthetic metal–diamond composite and obtained using PPTAW method. Full article