1. School of Mechanical and Electrical Engineering, Nanchang University, Nanchang 330031, China 2. State Key Laboratory of Tribology, Tsinghua University, Beijing 100084, China 3. Institute of Applied Physics, Jiangxi Academy of Sciences, Nanchang 330029, China
Cite this article:
Wenqin WANG, Zhaoman WANG, Yulong LI, De WANG, Miao LI, Qing CHEN. Wear Behavior of Fe-WC/Metal Double Layer Coatings Fabricated by Resistance Seam Weld Method. Acta Metall Sin, 2019, 55(4): 537-546.
Fe-WC/metal double layer coatings containing Fe-C-Si super hard alloy (SHA) particles and tungsten carbide (WC) particles were fabricated on Al7075 substrates by resistance seam welding method to improve the wear resistance of aluminum alloys. The micro-structure and phase compositions of the Fe-WC/metal double layer coatings with different WC particle sizes (fine and coarse) were investigated by SEM and EPMA. Nano-hardness of different phases in the coatings were investigated by nano-indentation test. Finally, the friction behavior of the two kinds of Fe-WC /metal double layer coatings were contrasted by ball-on-disc test using WC and SUS 304 balls. The results show that the thicknesses of Fe-WC composite/metal double layer coatings were about 600 μm. The microstructure of the coatings was: WC/Fe composite (wear resistance layer)+Fe/Al composite (metal interlayer)+Al7075 substrate. When WC ball was used as the static counterpart, the wear mechanism of the coatings with fine and coarse WC particles were severe abrasive wear and brittle fracture with little abrasive wear, respectively. When SUS304 was used as the static counterpart, the coating with fine WC powder was demonstrated difficulty to be abraded due to the protection of the iron oxide adhesive layer, and the other proved a little brittle fracture. Moreover, the wear rate of both coatings using SUS304 ball was lower than that of WC ball in the ball-on-disc test.
Fund: National Natural Science Foundation of China(No.51765041);The Tribology Science Fund of State Key Laboratory of Tribology(No.5KLTLF17B07);Key Research and Development Project of Jiangxi Province(No.20171BBE50022)
Fig.1 Cross-sectional microstructures of the Fe-WC/metal double layer coatings (SHA—super hard alloy)(a, b) overview of the Coating-F and Coating-C, respectively(c, d) Fe-WC layer of the Coating-F and Coating-C, respectively(e, f) metal interlayer of the Coating-F and Coating-C, respectively
Fig.2 EPMA mappings of Fe-WC/metal double layer coatings(a) Fe-WC layer of the Coating-F (b) Fe-WC layer of the Coating-C (c) metal interlayer of the Coating-F (d) metal interlayer of the Coating-C
Fig.3 Results of microindentation test in metal interlayer of Coating F(a) testing positions (b) nano-hardness curve in different positions (c~e) indentations in points 1~3, respectively
Fig.4
Fig.5 Formation mechanism of Coating-F by resistance seam welding method
Fig.6 Worn surfaces of Coating-F (a~c) and Coating-C (d~f) against WC ball after BOD test(a, d) overview of surfaces (b, e) SHA surfaces (c, f) WC surfaces
Fig.7 Worn surfaces of Coating-F (a~c) and Coating-C (d~f) against SUS304 ball after BOD test(a, d) overview of surfaces (b, e) SHA surfaces (c, f) WC surfaces
Fig.8 EDS elemental mappings of worn surfaces of Coating-F (a) and Coating-C (b) against WC ball after BOD test
Fig.9 EDS elemental mappings of worn surfaces of Coating-F (a) and Coating-C (b) against SUS304 ball after BOD test
Fig.10 EDS elemental mappings of wear scar of WC ball sliding against coatings after BOD test(a) Coating-F (b) Coating-C
Fig.11 EDS elemental mappings of wear scar of SUS304 ball sliding against coatings(a) Coating-F (b) Coating-C (c) enlarged image of Coating-C
1
Poletti C, Balog M, Simancik F, et al. High-temperature strength of compacted sub-micrometer aluminium powder [J]. Acta Mater., 2010, 58: 3781
2
Miller W S, Zhuang L, Bottema J, et al. Recent development in aluminium alloys for the automotive industry [J]. Mater. Sci. Eng., 2000, A280: 37
3
Wang Y Q, Wang Y, Chen P M, et al. Microstructure, corrosion and wear resistances of microarc oxidation coating on Al alloy 7075 [J]. Acta Metall. Sin., 2011, 47: 455
Xiong Y Y, Li N, Jiang H W, et al. Microstructural evolutions of AA7055 aluminum alloy under dynamic and quasi-static compressions [J]. Acta Metall. Sin. (Engl. Lett.), 2014, 27: 272
5
Man H C, Zhang S, Cheng F T. Improving the wear resistance of AA 6061 by laser surface alloying with NiTi [J]. Mater. Lett., 2007, 61: 4058
6
Wang L P, Gao Y, Hu L T, et al. Research status and prospect of electrodeposited functional gradient materials [J]. Surf. Technol., 2006, 35: 1
Aliofkhazraei M, Rouhaghdam A S. Fabrication of functionally gradient nanocomposite coatings by plasma electrolytic oxidation based on variable duty cycle [J]. Appl. Surf. Sci., 2012, 258: 2093
8
Tang J, Xiong J, Guo Z X, et al. Microstructure and properties of CVD coated on gradient cemented carbide with different WC grain size [J]. Int. J. Refract Met. Hard Mater., 2016, 61: 128
9
Pellizzari M. High temperature wear and friction behaviour of nitrided, PVD-duplex and CVD coated tool steel against 6082 Al alloy [J]. Wear, 2011, 271: 2089
10
Wang L, Fu Q G, Zhao F L. A novel gradient SiC-ZrB2-MoSi2 coating for SiC coated C/C composites by supersonic plasma spraying [J]. Surf. Coat. Technol., 2017, 313: 63
11
Yang Y, Li K Z, Zhao Z G, et al. HfC-ZrC-SiC multiphase protective coating for SiC-coated C/C composites prepared by supersonic atmospheric plasma spraying [J]. Ceram. Int., 2017, 43: 1495
12
Zhu C, Wang Y G, An L N, et al. Microstructure and oxidation behavior of conventional and pseudo graded NiCrAlY/YSZ thermal barrier coatings produced by supersonic air plasma spraying process [J]. Surf. Coat. Technol., 2015, 272: 121
13
Liu F C, Mao Y Q, Lin X, et al. Microstructure and high temperature oxidation resistance of Ti-Ni gradient coating on TA2 titanium alloy fabricated by laser cladding [J]. Opt. Laser. Technol., 2016, 83: 140
14
Zhang Y. Research on current status of fabrication methods for functionally graded material [J]. Hot Working Technol., 2012, 41: 14
14
张 勇. 功能梯度材料制备方法的研究现状 [J]. 热加工工艺, 2012, 41: 14
15
Cen Y D, Chen F R. Recent progress in numerical simulation of resistance seam welding [J]. Trans. Chin. Weld. Inst., 2016, 37(2): 123
Li Y Q, Zhao H, Zhao X H, et al. Numerical simulation of RSW temperature field during aluminum alloys LB-RSW [J]. Trans. Chin. Weld. Inst., 2009, 30(4): 29
Zhao X H, Feng J C. Pressure Welding Method and Equipment [M]. Beijing: China Machine Press, 2005: 1
17
赵熹华, 冯吉才. 压焊方法及设备 [M]. 北京: 机械工业出版社, 2005: 1)
18
Khosravi A, Halvaee A, Hasannia M H. Weldability of electrogalvanized versus galvanized interstitial free steel sheets by resistance seam welding [J]. Mater. Des., 2013, 44: 90
19
Wang W Q, Yamaguchi T, Nishio K. Microstructure and wear behavior of cermet/iron alloy cladding layers on A6061 alloy coated by resistance seam welding method [J]. Acta Metall. Sin. (Engl. Lett.), 2015, 28: 414
20
Wang W Q, Wang D, Yamaguchi T, et al. Comparative study of wear performance of ceramic/iron composite coatings under two different wear modes [J]. Surf. Coat. Technol., 2017, 309: 136
21
Wang W Q, Yamaguchi T, Nishio K. Structure of iron-based cladding layer on Al-Mg-Si alloy coated by a resistance seam welding method [J]. Mater. Trans., 2014, 55: 1698
22
Xu J S, Zhang X C, Xuan F Z, et al. Tensile properties and fracture behavior of laser cladded WC/Ni composite coatings with different contents of WC particle studied by in-situ tensile testing [J]. Mater. Sci. Eng., 2013, A560: 744
23
He L, Tan Y F, Wang X L, et al. Tribological properties of WC and CeO2 particles reinforced in-situ synthesized NiAl matrix composite coatings at elevated temperature [J]. Surf. Coat. Technol., 2014, 244: 123
24
Wang T G, Song B H, Hua W G, et al. Influence of process parameters on the performance uniformity of detonation gun sprayed WC-Co coatings [J]. Acta Metall. Sin., 2011, 47: 115
Zhang F G, Zhu X P, Wang M Y, et al. Surface modification of WC-Ni cemented carbide for seals by high-intensity pulsed ion beam irradiation [J]. Acta Metall. Sin., 2011, 47: 958
Farid A, Guo S J. On the processing, microstructure, mechanical and wear properties of cermet/stainless steel layer composites [J]. Acta Mater., 2007, 55: 1467
27
Bolelli G, Börner T, Milanti A, et al. Tribological behavior of HVOF- and HVAF-sprayed composite coatings based on Fe-Alloy+WC-12% Co [J]. Surf. Coat. Technol., 2014, 248: 104
28
Zhou S F, Dai X Q. Microstructure evolution of Fe-based WC composite coating prepared by laser induction hybrid rapid cladding [J]. Appl. Surf. Sci., 2010, 256: 7395
29
Tong X, Li F H, Kuang M, et al. Effects of WC particle size on the wear resistance of laser surface alloyed medium carbon steel [J]. Appl. Surf. Sci., 2012, 258: 3214
30
Melendez N M, Narulkar V V, Fisher G A, et al. Effect of reinforcing particles on the wear rate of low-pressure cold-sprayed WC-based MMC coatings [J]. Wear, 2013, 306: 185
31
Onuoha C C, Jin C X, Farhat Z N, et al. The effects of TiC grain size and steel binder content on the reciprocating wear behaviour of TiC-316L stainless steel cermets [J]. Wear, 2016, 350-351: 116
32
Gong T M, Yao P P, Zuo X T, et al. Zhong, Influence of WC carbide particle size on the microstructure and abrasive wear behavior of WC-10Co-4Cr coatings for aircraft landing gear [J]. Wear, 2016, 362-363: 135
33
Han J C, Jafari M, Park C G, et al. Microstructure-property relations in WC-Co coatings sprayed from combinatorial Ni-plated and nanostructured powders [J]. Mater. Charact., 2017, 129: 207
34
Zhou D W, Peng Y, Xu S H, et al. Microstructure and mechanical property of steel/Al alloy laser welding with Sn powder addition [J]. Acta Metall. Sin., 2013, 49: 959
Chen M J, Huang J K, He C C, et al. Thermodynamic analysis of the formation of Fe-Al-Zn intermetallic compounds in Al/galvanized steel interface [J]. Acta Metall. Sin., 2016, 52: 113
Wu Z Q, Xia Y, Li G, et al. Micro-mechanical properties of ceramic coating fabricated by plasma electrolytic oxidation on hot-dip aluminized steel [J]. Acta Metall. Sin., 2008, 44: 119
Bolelli G, Bonferroni B, Laurila J, et al. Micromechanical properties and sliding wear behaviour of HVOF-sprayed Fe-based alloy coatings [J]. Wear, 2012, 276-277: 29
38
Mi P B, Wang T, Ye F X. Influences of the compositions and mechanical properties of HVOF sprayed bimodal WC-Co coating on its high temperature wear performance [J]. Int. J.Refract. Met. Hard Mater., 2017, 69: 158
39
Kennedy F E, Lu Y, Baker I. Contact temperatures and their influence on wear during pin-on-disk tribotesting [J]. Tribol. Int., 2015, 82: 534
40
Farahani M V, Emadoddin E, Emamy M, et al. Effect of grain refinement on mechanical properties and sliding wear resistance of extruded Sc-free 7042 aluminum alloy [J]. Mater. Des., 2014, 54: 361
41
Lu Y, Baker I, Kennedy F E, et al. The effect of sliding velocity on the dry sliding wear of nanophase Fe30Ni20Mn25Al25 against yttria-stabilized zirconia [J]. Intermetallics, 2017, 83: 17
