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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 Cover

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

Materials Science-Poland
Volume 40 (2022): Issue 3 (September 2022)
By: Augustine Nana Sekyi Appiah,  Oktawian Bialas,  Marcin Żuk,  Artur Czupryński,  David Konadu Sasu and  Marcin Adamiak  
Open Access
|Dec 2022

Figures & Tables

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 PointNiCrBWC
P1Weight%6151303
Atom%64671013
P2Weight%4292443
Atom%4510131517
P3Weight%1--963
Atom%2--6929
P4Weight%4--923
Atom%92-6227

Chemical composition of PG 6503 MMC powder

Measured pointNiBWC
P1Weight%761221
Atom%85483
P2Weight%751231
Atom%81686
P3Weight%1-963
Atom%1-6632
P4Weight%1-972
Atom%2-7424

Geometrical properties and dilution ratio of prepared hardfaced layers

Sample IDLayer height, R (mm)Penetration depth, P (mm)Layer width, w (mm)Dilution, D (%)
PG-12.90.2231.1
PG-22.70.5244.5
PG-31.70.3233.7
PG-42.20.4244.3
PE-52.20.2240.9
PE-62.60.4232.1
PE-72.81.4257.8
PE-83.01.0256.6

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 IDTest 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-11197.9632197.62360.33960.315411.193528.17714.7
2193.3204193.02920.2912
PG-21206.7898206.55730.23250.256711.193522.93295.7
2211.2178210.93690.2809
PG-31198.3808197.96870.41210.368911.193532.95664.0
2193.7380193.41230.3257
PG-41225.5144225.22070.29370.317911.193528.40044.7
2230.1572229.81510.3421
PTAW hardfaced layer (NiCrSiB + 45% WC)
PE-51228.8165228.48680.32970.35399.827436.01163.7
2224.1737223.79560.3781
PE-61226.3483226.01480.33350.30939.827431.47324.2
2230.9911230.70600.2851
PE-71229.3361228.42980.90630.78219.827479.58361.7
2233.9789233.3210.6579
PE-81224.0304223.68030.35010.37429.827438.07723.5
2219.3876218.98930.3983
Reference material – AR400 steel 4
H1 104.6219103.49711.12481.03187.7836132.56071.0
H2 111.7377110.79890.9388

Microhardness across the cross-section of hardfaced layers

Sample IDMicrohardness of matrix, HVMicrohardness of carbides, HV
MeanStandard deviationMeanStandard deviation
PG-15915.22,41362.9
PG-257310.22,12933.3
PG-36872.42,16376.1
PG-467318.52,27549.5
PE-588918.02,34938.7
PE-684523.22,43624.1
PE-788923.82,34361.6
PE-889316.12,39180.5

Surface hardness of hardfaced layers

SpecimenRockwell hardness (HRC)
MeanStandard deviation
PG-146.30.5
PG-247.32.6
PG-347.72.5
PG-448.31.2
PE-558.33.7
PE-652.73.3
PE-755.32.9
PE-855.71.2

PTAW parameters for sample preparation

Coating/sample IDPowder usedCurrent (A)Travel speed, V (mm/s)PGFR (l/min)
PG-1PG 65031101.31.0
PG-2PG 65031101.31.2
PG-3PG 65031501.31.2
PG-4PG 65031101.31.5
PE-5PE 82141101.31.0
PE-6PE 82141101.31.2
PE-7PE 82141501.31.2
PE-8PE 82141101.31.5
DOI: https://doi.org/10.2478/msp-2022-0033 | Journal eISSN: 2083-134X | Journal ISSN: 2083-1331
Journal RSS Feed
Language: English
Page range: 42 - 63
Submitted on: Oct 24, 2022
|
Accepted on: Nov 11, 2022
|
Published on: Dec 31, 2022
Published by: Wroclaw University of Science and Technology
In partnership with: Paradigm Publishing Services
Publication frequency: 4 issues per year
Keywords:
microhardness,
microstructure,
mechanical properties,
scanning electron microscopy,
dilution,
heat affected zone
Related subjects:
Materials sciences,
Materials sciences, other,
Nanomaterials,
Functional and smart materials,
Materials characterization and properties

© 2022 Augustine Nana Sekyi Appiah, Oktawian Bialas, Marcin Żuk, Artur Czupryński, David Konadu Sasu, Marcin Adamiak, published by Wroclaw University of Science and Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

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