Surface Protection for Enhanced Materials Performance: Science and Technology: Wear-Resistant and Tribological Coatings
Sponsored by: MS&T Organization
Program Organizers: Rodney Trice, Purdue University; Dongming Zhu, NASA Glenn Research Center; Daniel Mumm, University of California-Irvine; Hua-Tay Lin, Oak Ridge National Laboratory; Pravansu Mohanty, University of Michigan; Yutaka Kagawa, The University of Tokyo; Kang Lee, Rolls Royce; Charles Kay, ASB Industries, Inc.; Luc Pouliot, TECNAR Automation Ltd.
Monday 2:00 PM
October 17, 2011
Room: D230
Location: Greater Columbus Convention Center
Session Chair: Rodney Trice, Purdue University; Douglas Wolfe, Penn State
2:00 PM Invited
Erosion Resistant Coatings for the Suppression of Leading Edge Burr: Modeling and Testing: Douglas Wolfe1; 1The Penn State University
Erosion has become increasingly important in the last few years for military aircraft, especially compressor blisks and helicopter components. When aircraft take-off and land, vortexes are formed which often result in hard particles of sand, dust and ice incorporated with the air flow. These hard particles impact compressor blisks at various angles resulting in severe erosion and deformation leading to decreased efficiency and performance. The mechanism of erosion due to solid particle impingement is very complex and poorly understood. No single coating material exists which offers erosion resistance properties at both high and low angle sand impingement. Current efforts in applying monolithic and multilayer binary and ternary nitride coatings will be discussed with regards to processing, characterization, and erosion testing. The working environment such as erosive particle size, shape, type, and distribution, combined with intrinsic substrate material properties will generally dictate whether monolithic or multilayer coating systems will perform better.
2:40 PM
Slurry Erosion Resistance of Overlays Containing Boride Crystals Oriented Perpendicularly to the Wearing Surface: Serge Dallaire1; 1SYNTHESARC INC.
Components exposed to the flow of liquid solutions containing hard particles experience significant material loss. For defined slurry conditions, the extent of damage to the components depends upon their microstructure and the slurry particle impingement angles. This paper presents the research work carried on to develop a gas metal arc welding overlay that resists slurry erosion at both low and high particle angles. Overlays containing hard Fe2B crystals in a supporting matrix enriched in toughening elements have been considered. Cored wires of specific compositions deposited with adapted welding parameters produce weld overlays presenting a peculiar microstructure. These iron boride-based overlays contain fine elongated boride crystals aligned mainly perpendicularly to the wearing surface. This peculiar microstructure is responsible for the outstanding slurry erosion resistance observed at both impinging angles of 30° and 90°.
3:00 PM
Mechanical and Physical Properties of Carbon S-Phase on Stainless Steel, Produced by Carbon Supersaturation: Ralph Hunger1; 1Bodycote Hardiff GmbH
While the excellent corrosion resistance of austenitic stainless steels has resulted in wide commercial application of these materials, poor tribological behaviour, especially low abrasive / adhesive wear resistance and a tendency for fretting, has prevented the use of these materials in applications where both corrosion and wear resistance are required. For more than 20 years, the Kolsterising process has offered a solution to the industry; enhanced wear properties and unaltered corrosion resistance. Suitable for austenitic and duplex stainless steels and nickel base alloys, this thermo-chemical diffusion process enriches the austenitic surface with carbon, forming a carbon supersaturated layer or carbon S-phase while avoiding the carbide precipitation that causes sensitization. The presentation compares the properties of treated and untreated austenitic stainless steels. Results show improvement in wear resistance and fatigue life with Kolsterising, while corrosion resistance is unaffected.
3:20 PM Break
3:40 PM Invited
Wear Resistant Hard Facing and Cutting Assistant Hard Coating in Oil and Gas Drilling Applications: Jing Xu1; Hendrik John1; Denis Kopecki1; 1Baker Hughes
This paper studies some application of hard materials in the oil and gas drilling industry. Focus is made on protective ceramics and carbide hard-facing against abrasive and erosive wear, as well as the super-hard boride coating for down-hole cutting application. Two different wears are investigated, namely the wet sand/rubber wheel abrasive wear and the high speed particle/water jet erosive wear. Comparison is made among five types of engineering ceramics and two types of tungsten carbide varying cobalt contents. Results showed that size ratio between hard materials grain size and erodent/abrasive particle size plays role in wear characteristics by affecting the wearing mechanisms. In addition, this paper discusses some boride coating for downhole cutting applications especially to cut through high strength nickel alloys such as Inconel718. The boride coating shows a unique combination of high toughness and high wear resistance, which makes it unique for down-hole cutting conditions.
4:20 PM
Development of Economical Multifunctional Composite Coating for Energy Efficient Sliding Systems: Sudeep Ingole1; Masatoshi Kuniyoshi1; Rajeshwari Paluri1; 1Texas A&M University
Due to Environment Protection Agency’s strict norms to improve energy efficiency and environmental safety, reducing frictional losses of the sliding systems are crucial. Moving parts of machinery (frictional interfaces) serve as sources for the loss of energy which reflect on the efficiency of the machine. Multifunction ceramic composites coatings for friction applications pose great potentials for these applications. Newly developed fly ash multi-functional composites showed promising mechanical properties and frictional performance. These coatings have potential applications in low friction applications due the presence of low friction components in the matrix. They were synthesized using the combination of dip coat and boronizing on steel substrate. These coatings showed good interface that has boronized phases grown into the steel substrate whereas fly ash components served as hard coat. This is first time ever to demonstrate this unique combination of coating development. This presentation will discuss the coating characteristics and their tribological performance.
4:40 PM
Diamond Coated Mechanical Seals in Working Conditions: Wear Performance Evaluation: José Santos1; Victor Neto1; David Ruch2; José Grácio1; 1Department of Mechanical Engineering, Centre for Mechanical Technology & Automation, University of Aveiro; 2Department of Advanced Materials and Structures, Centre de Recherche Public Henri Tudor
A mechanical seal is a type of seal used in rotating equipment, such as pumps and compressors. It consists of a mechanism that promotes the connection of rotating shaft to the housing of the equipments, preventing leakage or avoiding contamination. A common cause of failure of these devices is there end face wear out, thus the use of a hard, smooth and wear resistant coating such as nanocrystalline diamond film would be of great importance to improve their working performance and increase their lifetime. In this work diamond coatings were deposited by hot filament chemical vapour deposition on WC mechanical face seals and tested in real work conditions. The coated seals were examined using Scanning Electron Microscopy, Raman and optical profilometry before and after the wear testing.
5:00 PM
Performance of Nanocrystalline Diamond Coated Micromolding Tools: Victor Neto1; Mónica Oliveira1; José Grácio1; 1University of Aveiro
The injection molding of small polymeric parts with features at the microscale are being an increased industry demand. Nevertheless, the production of mold tools with this level of features impose new constraint to mold producer’s, namely the degree of the features acceptable tolerances and the consequent selection of the materials that can resist the wear that the polymeric material will impose. CVD diamond films present a set of properties (high hardness and wear resistance, high thermal conductivity, and high resistant to corrosion) that points it as an ideal candidate to surface engineer injection micromolding tools. Till now, the evaluation of diamond coatings on polymeric molding surface show evidence of a positive performance, nevertheless further research is required, namely the use of nanocrystalline diamond films on complex structured surfaces. In this work, it is presented the results of nanocrystalline diamond coated molding structures and an evaluation of their performance.
5:20 PM
Sliding Wear Behavior of Ni-Al Coatings Processed In-Situ by Plasma Transferred Arc: Cristiano Brunetti1; Felipe Mendes2; Giuseppe Pintaude2; Ana Sofia D´Oliveira1; 1UFPR - Federal University of Paraná; 2UTFPR - Technological University of Paraná
Ni-Al intermetallic alloys are attractive materials whenever wear resistance is required. This study analyzed Ni-Al coatings processed in-situ by PTA and their performance under sliding wear conditions. Coatings were processed with Ni and Al elemental powders onto an AISI 1020 steel substrate, to minimize the diversity of alloying elements diffusing from the substrate. Deposition current and torch travel speeds were varied to produce different dilution levels and therefore, modifying the iron (Fe) content in the coatings. Characterization of coatings included X-ray diffraction, scanning electron microscopy, and instrument indentation tests. The wear tests of coatings were carried out in a pin-on-disc tribometer against AISI 420 stainless steel discs. The normal loads were selected to reproduce different wear mechanisms, either dominated by oxidation or by plastic deformation. A wear map of the effect of Fe in the behavior of Ni-Al coatings is put forward and discussed.