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Hardfacing of mild steel with wear-resistant Ni-based powders containing tungsten carbide particles using powder plasma transferred arc welding technology

Augustine Nana Sekyi Appiah
Augustine Nana Sekyi Appiah
, 
Oktawian Bialas
Oktawian Bialas
, 
Marcin Żuk
Marcin Żuk
, 
Artur Czupryński
Artur Czupryński
, 
David Konadu Sasu
David Konadu Sasu
 e 
Marcin Adamiak
Marcin Adamiak
   | 31 dic 2022
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Pubblicato online: 31 dic 2022
Pagine: 42 - 63
Ricevuto: 24 ott 2022
Accettato: 11 nov 2022
DOI: https://doi.org/10.2478/msp-2022-0033
Parole chiave
© 2022 Augustine Nana Sekyi Appiah et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1

Schematic diagrams showing the dimensions of the prepared samples. (A) Dimensions of the prepared mild steel plate to be used as a substrate material. (B) Cross-section of the final material after deposition of the hardfaced layer onto the substrate material, showing the range of thickness of the hardfaced layers for the various samples
Schematic diagrams showing the dimensions of the prepared samples. (A) Dimensions of the prepared mild steel plate to be used as a substrate material. (B) Cross-section of the final material after deposition of the hardfaced layer onto the substrate material, showing the range of thickness of the hardfaced layers for the various samples

Fig. 2

Images of prepared hardfaced layers on the surface of substrate material: (A) PG-1, (B) PG-2, (C) PG-3, (D) PG-4, (E) PE-5, (F) PE-6, (G) PE-7, and (H) PE-8
Images of prepared hardfaced layers on the surface of substrate material: (A) PG-1, (B) PG-2, (C) PG-3, (D) PG-4, (E) PE-5, (F) PE-6, (G) PE-7, and (H) PE-8

Fig. 3

SEM images of MMC powders; (A) PE 8214 (B) PG 6503. MMC, metal matrix composite; SEM, scanning electron microscopy
SEM images of MMC powders; (A) PE 8214 (B) PG 6503. MMC, metal matrix composite; SEM, scanning electron microscopy

Fig. 4

EDS of powder PE 8214 showing chemical compositions. EDS, energy dispersive X-ray spectroscopy
EDS of powder PE 8214 showing chemical compositions. EDS, energy dispersive X-ray spectroscopy

Fig. 5

EDS of powder PG 6503 showing chemical compositions. EDS, energy dispersive X-ray spectroscopy
EDS of powder PG 6503 showing chemical compositions. EDS, energy dispersive X-ray spectroscopy

Fig. 6

Micrographs of the prepared samples at 500× magnification: (A) PG-1, (B) PG-2, (C) PG-3, (D) PG-4, (E) PE-5, (F) PE-6, (G) PE-7, and (H) PE-8
Micrographs of the prepared samples at 500× magnification: (A) PG-1, (B) PG-2, (C) PG-3, (D) PG-4, (E) PE-5, (F) PE-6, (G) PE-7, and (H) PE-8

Fig. 7

EDS maps showing the chemical composition of the microstructure of the hardfaced layer (A) area under observation (B–G) elemental distribution maps. EDS, energy dispersive X-ray spectroscopy
EDS maps showing the chemical composition of the microstructure of the hardfaced layer (A) area under observation (B–G) elemental distribution maps. EDS, energy dispersive X-ray spectroscopy

Fig. 8

Light microscopy cross-sectional image of samples showing the distribution of carbides in the Ni-based matrix under conditions of variable plasma arc current. (A) Sample PE-2 with PTA current of 110 A; (B) Sample PE-3 with PTA current of 150 A; (C) Sample PG-6 with PTA current of 110 A; and (D) Sample PG-7 with PTA current of 150 A. PTA, plasma transferred arc
Light microscopy cross-sectional image of samples showing the distribution of carbides in the Ni-based matrix under conditions of variable plasma arc current. (A) Sample PE-2 with PTA current of 110 A; (B) Sample PE-3 with PTA current of 150 A; (C) Sample PG-6 with PTA current of 110 A; and (D) Sample PG-7 with PTA current of 150 A. PTA, plasma transferred arc

Fig. 9

Stereoscopic cross-sectional image of samples showing the HAZ under conditions of variable PTA current. (A) Sample PE-2 with PTA current of 110 A; (B) Sample PG-6 with PTA current of 110 A; (C) Sample PE-3 with PTA current of 150 A; and (D) Sample PG-7 with PTA current of 150 A. HAZ, heat affected zones; PTA, plasma transferred arc
Stereoscopic cross-sectional image of samples showing the HAZ under conditions of variable PTA current. (A) Sample PE-2 with PTA current of 110 A; (B) Sample PG-6 with PTA current of 110 A; (C) Sample PE-3 with PTA current of 150 A; and (D) Sample PG-7 with PTA current of 150 A. HAZ, heat affected zones; PTA, plasma transferred arc

Fig. 10

Images of samples after penetration test showing the origin and depth of cracks on the surfaces of the hardfaced layers (A) PG-1, (B) PG-2, (C) PG-3, (D) PG-4, (E) PE-5, (F) PE-6, (G) PE-7, and (H) PE-8
Images of samples after penetration test showing the origin and depth of cracks on the surfaces of the hardfaced layers (A) PG-1, (B) PG-2, (C) PG-3, (D) PG-4, (E) PE-5, (F) PE-6, (G) PE-7, and (H) PE-8

Fig. 11

Digital images of the surfaces of as-deposited hardfaced layers showing crack development and surface porosity. (A) PG-1, (B) PG-2, (C) PG-3, (D) PG-4, (E) PE-5, (F) PE-6, (G) PE-7, and (H) PE-8
Digital images of the surfaces of as-deposited hardfaced layers showing crack development and surface porosity. (A) PG-1, (B) PG-2, (C) PG-3, (D) PG-4, (E) PE-5, (F) PE-6, (G) PE-7, and (H) PE-8

Fig. 12

(A) Graphs showing how the average volume losses of the specimen compare with the average volume loss of the reference material; (B) Relative abrasive wear resistance with changes in PGFR
(A) Graphs showing how the average volume losses of the specimen compare with the average volume loss of the reference material; (B) Relative abrasive wear resistance with changes in PGFR

Fig. 13

Schematic of the geometrical parameters of the cross-section of the final material after deposition of the hardfaced layer onto the substrate material, showing the reinforcement area, fusion zone area, and HAZ. HAZ, heat affected zone
Schematic of the geometrical parameters of the cross-section of the final material after deposition of the hardfaced layer onto the substrate material, showing the reinforcement area, fusion zone area, and HAZ. HAZ, heat affected zone

Fig. 14

Comparison of HAZ with an increase in PTA current. (A) The HAZ is smaller with a lower value of PTA current at 110 A; (B) The HAZ is larger with an increased value of PTA current at 150 A. HAZ, heat affected zones; PTA, plasma transferred arc
Comparison of HAZ with an increase in PTA current. (A) The HAZ is smaller with a lower value of PTA current at 110 A; (B) The HAZ is larger with an increased value of PTA current at 150 A. HAZ, heat affected zones; PTA, plasma transferred arc

Chemical composition of PE 8214 MMC powder

Measured Point Ni Cr B W C
P1 Weight% 61 5 1 30 3
Atom% 64 6 7 10 13
P2 Weight% 42 9 2 44 3
Atom% 45 10 13 15 17
P3 Weight% 1 - - 96 3
Atom% 2 - - 69 29
P4 Weight% 4 - - 92 3
Atom% 9 2 - 62 27

Chemical composition of PG 6503 MMC powder

Measured point Ni B W C
P1 Weight% 76 1 22 1
Atom% 85 4 8 3
P2 Weight% 75 1 23 1
Atom% 81 6 8 6
P3 Weight% 1 - 96 3
Atom% 1 - 66 32
P4 Weight% 1 - 97 2
Atom% 2 - 74 24

Geometrical properties and dilution ratio of prepared hardfaced layers

Sample ID Layer height, R (mm) Penetration depth, P (mm) Layer width, w (mm) Dilution, D (%)
PG-1 2.9 0.2 23 1.1
PG-2 2.7 0.5 24 4.5
PG-3 1.7 0.3 23 3.7
PG-4 2.2 0.4 24 4.3
PE-5 2.2 0.2 24 0.9
PE-6 2.6 0.4 23 2.1
PE-7 2.8 1.4 25 7.8
PE-8 3.0 1.0 25 6.6

Results of the metal-mineral abrasive wear resistance tests concerning the surface layer PPTAW deposition of NiSiB + 60% WC and NiCrSiB + 45% WC composite powders on mild steel in comparison with the abrasive wear resistance of abrasion-resistant steel AR400

Sample ID Test No. Mass before test (g) Mass after test (g) Mass loss (g) Average mass loss (g) Material density (g/cm3) Average volume loss (mm3) Relative abrasive wear resistance*
PTAW hardfaced layer (NiSiB + 60% WC)
PG-1 1 197.9632 197.6236 0.3396 0.3154 11.1935 28.1771 4.7
2 193.3204 193.0292 0.2912
PG-2 1 206.7898 206.5573 0.2325 0.2567 11.1935 22.9329 5.7
2 211.2178 210.9369 0.2809
PG-3 1 198.3808 197.9687 0.4121 0.3689 11.1935 32.9566 4.0
2 193.7380 193.4123 0.3257
PG-4 1 225.5144 225.2207 0.2937 0.3179 11.1935 28.4004 4.7
2 230.1572 229.8151 0.3421
PTAW hardfaced layer (NiCrSiB + 45% WC)
PE-5 1 228.8165 228.4868 0.3297 0.3539 9.8274 36.0116 3.7
2 224.1737 223.7956 0.3781
PE-6 1 226.3483 226.0148 0.3335 0.3093 9.8274 31.4732 4.2
2 230.9911 230.7060 0.2851
PE-7 1 229.3361 228.4298 0.9063 0.7821 9.8274 79.5836 1.7
2 233.9789 233.321 0.6579
PE-8 1 224.0304 223.6803 0.3501 0.3742 9.8274 38.0772 3.5
2 219.3876 218.9893 0.3983
Reference material – AR400 steel 4
H1 104.6219 103.4971 1.1248 1.0318 7.7836 132.5607 1.0
H2 111.7377 110.7989 0.9388

Microhardness across the cross-section of hardfaced layers

Sample ID Microhardness of matrix, HV Microhardness of carbides, HV
Mean Standard deviation Mean Standard deviation
PG-1 591 5.2 2,413 62.9
PG-2 573 10.2 2,129 33.3
PG-3 687 2.4 2,163 76.1
PG-4 673 18.5 2,275 49.5
PE-5 889 18.0 2,349 38.7
PE-6 845 23.2 2,436 24.1
PE-7 889 23.8 2,343 61.6
PE-8 893 16.1 2,391 80.5

Surface hardness of hardfaced layers

Specimen Rockwell hardness (HRC)
Mean Standard deviation
PG-1 46.3 0.5
PG-2 47.3 2.6
PG-3 47.7 2.5
PG-4 48.3 1.2
PE-5 58.3 3.7
PE-6 52.7 3.3
PE-7 55.3 2.9
PE-8 55.7 1.2

PTAW parameters for sample preparation

Coating/sample ID Powder used Current (A) Travel speed, V (mm/s) PGFR (l/min)
PG-1 PG 6503 110 1.3 1.0
PG-2 PG 6503 110 1.3 1.2
PG-3 PG 6503 150 1.3 1.2
PG-4 PG 6503 110 1.3 1.5
PE-5 PE 8214 110 1.3 1.0
PE-6 PE 8214 110 1.3 1.2
PE-7 PE 8214 150 1.3 1.2
PE-8 PE 8214 110 1.3 1.5
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