Dry sliding wear behaviors of Fe-based amorphous metallic coating synthesized by d-gun spray
Introduction
Recently, amorphous alloys have attracted much attention because of their remarkable mechanical properties including ultrahigh strength, excellent hardness, superior corrosion and wear resistance. [1], [2], [3] Among the amorphous alloys, Fe-based amorphous alloys are considered as potential engineering materials due to their relatively low cost and excellent mechanical properties [4], [5], [6], [7], [8]. However, the highly-localized shear bands and inhomogeneous shear deformation behavior at room temperature lead to the catastrophic brittle fracture in a shear mode, which seriously limited the engineering application of the Fe-based amorphous alloys [9, 10]. In order to expand the industrial application fields of the Fe-based metallic glass, the route of spraying as coating has been recognized as an efficient way to overcome this drawback.
Thermal spraying technology, a convenient and economical coating preparation technology [11], [12], [13], has been widely used to prepare amorphous coatings, such as high-velocity oxygen fuel (HVOF) spray [14, 15], high-velocity air fuel (HVAF) spray [16, 17], air plasma spray (APS) [18, 19], cold spray [20, 21] and detonation gun (D-gun) spray [22, 23]. For example, Sadeghi et al. [16] fabricated Fe-based amorphous coatings using HVOF and HVAF and discussed the effects of different thermal spraying technologies on the corrosion resistance of the Fe-based amorphous coatings. Zhou et al. [24] prepared Fe-based amorphous coatings by using the APS and found that Ar flow rate had a significant effect on the amorphous content and microhardness of amorphous coatings. Su et al. [21] prepared Fe-based amorphous coatings via cold spraying and HVAF spray, and the results indicated that the cold spray method can prepare denser amorphous coatings with higher amorphous phase content. Xie et al. [25] fabricated two kinds of Fe-based amorphous coatings by d-gun spray and found that the wear mechanism of amorphous coatings significantly depends on the amorphous content and porosity. Among the thermal spray techniques, d-gun spray uses the detonation phenomenon to heat and accelerate the powder particles, and then deposited them on the substrate materials. By controlling the ratio of the combustion gasses, the flight velocity of the powder particles are accelerated to 1200 m s − 1. Such high kinetic energy will make the hot particles (only skin of particles are melted) severely impact the substrate [26], resulting in a very dense and strong coatings. Due to the ultra-high particle flight speed and lower operating temperature, d-gun spray will be very helpful to prepare an amorphous coating with denser and higher amorphous phase content. Therefore, detonation gun spraying may become a very effective amorphous coating preparation technology.
In practical engineering applications, structural parts will inevitably come into contact with each other and cause wear behavior under various wear conditions. Then in order to obtain optimal wear service performance, understanding the wear mechanism of amorphous coating wear in a variety of conditions no doubt become a hot topic amorphous coatings. Therefore, a lot of works have been done to investigate the wear mechanism of Fe-based amorphous coatings prepared by different methods (such as HVOF [27], [28], [29], [30], HVAF [17, 31], APS [19, 32], cold spray [21] and d-gun spray [25] etc.) under various wear conditions. Zhang et al. [28] studied the wear behavior of Fe-based amorphous coatings deposited by HVOF spray. The result showed that the wear rate was more sensitive to the sliding speed than that of normal load and the wear mechanism is mainly oxidative wear accompanied with delamination wear. Guo et al. [17] reported that the wear resistance of Fe-based amorphous coatings fabricated by HVAF spray were correlated with microhardness, Young's modulus, and ratios of H/Er and H3/Er, the wear rate increased obviously with the increase of normal load, with the wear mechanisms of delamination, abrasive and oxidation wear. Zhang et al. [32] indicated that the particle sizes had a significant influence on the wear resistance of Fe-based amorphous coatings deposited by APS spray, and the dominating wear mechanism was fatigue wear accompanied with oxidative wear. Obviously, the wear behavior of Fe-based amorphous coatings prepared by different methods is different due to the coating density, amorphous phase content, microhardness and other factors. Given the advantages of the amorphous coating prepared by the d-gun spray, studying the microstructure changes of Fe-based amorphous coatings prepared by d-gun spray under different loads and sliding speeds will be very helpful for understanding the wear mechanism, and it can lay a theoretical foundation for the engineering application of Fe-based amorphous coatings prepared by d-gun spray.
In this paper, the Fe-based amorphous coating was prepared on a 9Ni substrate by the d-gun spray, and then the wear behaviors of the Fe-based amorphous coating were investigated under different sliding speed (0.1 m s − 1, 0.25 m s − 1, 0.5 m s − 1 and 1 m s − 1) and different normal load (5 N, 10 N and 15 N). In order to evaluate the wear resistance of Fe-based amorphous coatings and understand their wear mechanisms under different wear conditions, the microstructure, phase structure, and surface microhardness of Fe-based amorphous coatings before and after wear tesings were studied in detail.
Section snippets
Experimental
Fe-based amorphous metallic powder (Cr 25–27, Mo 16–18, C 2.0–2.5, B 2.0–2.2, Fe balance (wt.%)) was deposited on 9Ni steel substrate by using detonation spray system (АДМ–4Д) to obtain amorphous coating. The substrate, 9Ni steel, was machined into a dimension of ø25 mm × 5 mm. Before spraying, all substrates were cleaned with an acetone and alcohol solution to remove greasy dirt and then sandblasted with alumina abrasive for obtaining the clean surface to enhance the bonding strength between
Characterization of the Fe-based amorphous powders
Fig. 1a shows the SEM image of the Fe-based gas-atomized amorphous powders used as feedstock for the d-gun spray. One can see that most of the powder particles exhibit a spherical morphology and a very smooth surface, indicating that the powder particles have a good flowability for the d-gun spray process. Fig. 1b shows the size distribution of the powder particles. Although the particle size displays a wide distribution with diameter ranging from 10 μm to 60 μm, the main size is distributed in
Discussion
The preceding experimental results (as shown in Figs. 5 and 6) show that the wear rate of the present Fe-based amorphous coating is obviously affected by the sliding speeds (0.1 m s − 1~1.0 m s − 1) and normal loads (5 N~10 N). This phenomenon is mainly due to the oxidation behavior and the phase transformation (amorphous crystallization) behavior of the Fe-based amorphous coating caused by frictional heat generation during the frictional sliding process.
In the process of dry friction and wear,
Conclusions
In this work, the Fe-based amorphous coating without significant crystallization phenomenon was prepared on a 9Ni substrate by detonation spray method. The dry silding wear mechanisms of the present Fe-based amorphous coating against Si3N4 ball have been studied in detail under the normal load of 5 N~15 N and the sliding speed of 0.1 m s − 1~1.0 m s − 1. The main conclusions are as follows:
- (1)
The Fe-based amorphous coating prepared by d-gun spray displays a almost identical amorphous structure and
CRediT authorship contribution statement
Xuqiang Li: Data curation, Writing - original draft. Haimin Zhai: Conceptualization, Writing - review & editing. Wensheng Li: Supervision, Project administration. Shuai Cui: Methodology, Formal analysis. Weichao Ning: Visualization, Investigation. Xiaolai Qiu: Funding acquisition.
Declaration of Competing Interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Acknowledgments
Haimin Zhai would like to thank the Natural Science Foundation of China (No. 51901092). Wensheng Li is grateful to the Supporting Program of National Natural Science Foundation of China (51674130) and the National High-end Foreign Experts Program of China (GDT20186200331), and the International Science and Technology Correspondent Program of Gansu province (17JR7WA017).and the program of “Science and Technology International Cooperation Demonstrative Base of Metal Surface Engineering along the
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2023, Journal of Non-Crystalline SolidsCitation Excerpt :For example, Hua et al. [20] found that the wear rates of Fe-based amorphous alloy against different counterpart materials increased in the order of Si3N4, ZrO2, and Al2O3. Li et al. [21] prepared Fe-based ACs by detonation spray, and found that the wear behavior of coatings was sensitive to the sliding speed, and the wear mechanism changed from oxidative wear to delamination with the increase of sliding speed. In real working conditions, the wear environment is also an unignorable external factor in influencing the wear performance of coatings and dominating the wear mechanism [22].