High-Precision Determination of Residual Stress of As-Sprayed and Ground WC-10Co-4Cr Coating Using Optimized XRD-sin²ψ Technique

Abstract:

Thermally sprayed tungsten carbide-based coatings deposited by High Velocity Oxygen Fuel (HVOF) has been widely developed for its high corrosion and wear resistance. The finishing of the coated surface by grinding process is essential because of the high surface roughness of carbide coatings. Residual stresses existing in most hard coatings have significant influence on the adhesion, mechanical properties and tribological performance. The present study investigated the effect of grinding process on the residual stress of WC-10Co-4Cr coating by HVOF. The residual stress of coating was measured by the X-ray diffraction (XRD) technique using sin²ψ method. In addition, the effect of diffraction peak positioning method on the accuracy of residual stress of WC-10Co-4Cr coating was determined in the XRD technique. Four peak positioning methods and their effects on the accuracy of X-ray diffraction (XRD) residual stress measurement are considered. The results showed that the compressive residual stress of the WC-10Co-4Cr coating increase after grinding process. The parabolic method was selected for the peak positioning to measure the precise residual stress of HVOF-deposited WC-10Co-4Cr coating.

• Periodical: Key Engineering Materials (Volume 748)
• Pages: 381-385
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.748.381
• Online since: August 2017
• Authors: Maedeh Sadat Zoei*, Mohamad Hosein Sadeghi, Mehdi Salehi
• Keywords: Grinding, HVOF, Residual Stress, WC-10Co-4Cr, XRD-sin²ψ Technique

References

[1] T.N. Rhys-Jones, The use of thermally sprayed coatings for compressor and turbine applications in aero engines, Surf. Coat. Technol. 42(1) (1990) 1-11.

DOI: 10.1016/0257-8972(90)90109-p

[2] S. Hong, Y.P. Wu, W.W. Gao, B. Wang, W.M. Guo, J.R. Lin, Microstructural characterization and microhardness distribution of HVOF sprayed WC-10Co-4Cr coating, Surf. Eng. 30(1) (2014) 53-58.

DOI: 10.1179/1743294413y.0000000184

[3] M. Xie, S. Zhang, M. Li, Comparative investigation on HVOF sprayed carbide-based coatings, Appl. Surf. Sc. 273 (2013) 799-805.

DOI: 10.1016/j.apsusc.2013.03.010

[4] K. Murugan, A. Ragupathy, V. Balasubramanian, K. Sridhar, Optimizing HVOF spray process parameters to attain minimum porosity and maximum hardness in WC–10Co–4Cr coatings, Surf. Coat. Technol. 247 (2014) 90-102.

DOI: 10.1016/j.surfcoat.2014.03.022

[5] S. Hong, Y. Wu, Y. Zheng, B. Wang, W. Gao, G. Li, G. Ying, J. Lin, Effect of spray parameters on the corrosion behavior of HVOF sprayed WC-Co-Cr Coatings, J. Mater. Eng. Perform. 23(4) (2014) 1434-1439.

DOI: 10.1007/s11665-014-0865-3

[6] J.K.N. Murthy, D.S. Rao, B. Venkataraman, Effect of grinding on the erosion behavior of a WC–Co–Cr coating deposited by HVOF and detonation gun spray processes, Wear 249(7) (2001) 592-600.

DOI: 10.1016/s0043-1648(01)00682-2

[7] Thermal Spraying: Practice, Theory, and Application, American Welding Society, (1985).

[8] G.S. Schajer, Practical Residual Stress Measurement Methods; John Wiley & Sons, (2013).

[9] Q. Luo, A.H. Jones, High-precision determination of residual stress of polycrystalline coatings using optimised XRD-sin2ψ technique, Surf. Coat. Technol. 205(5) (2010) 1403-1408.

DOI: 10.1016/j.surfcoat.2010.07.108

[10] E. Kula, Residual stress and stress relaxation (Vol. 28), Springer Science & Business Media, (2013).

[11] N.V. Demidova, X.J. Wu, R. Liu, A fracture toughness model for brittle coating on ductile substrate under indentation loading, Eng. Fract. Mech. 82 (2012) 17-28.

DOI: 10.1016/j.engfracmech.2011.11.018

[12] C. Lyphout, P. Nylén, A. Manescu, T. Pirling, Residual stresses distribution through thick HVOF sprayed Inconel 718 coatings, J. Therm. Spray Technol. 17(5-6) (2008) 915-923.

DOI: 10.1007/s11666-008-9242-9

[13] S. Malkin, C. Guo, Thermal analysis of grinding, CIRP Annals-Manufacturing Technology, 56(2) (2007) 760-782.

DOI: 10.1016/j.cirp.2007.10.005

[14] K. Salonitis, On surface grind hardening induced residual stresses, Procedia CIRP, 13 (2014) 264-269.

DOI: 10.1016/j.procir.2014.04.045

[15] I.D. Marinescu, M.P. Hitchiner, E. Uhlmann, W.B. Rowe, I. Inasaki, Handbook of machining with grinding wheels, CRC Press, (2006).

DOI: 10.1201/9781420017649