Abstract
Ni–Al bronze (NAB) was coated with Stellite-6 through gas-fueled high-velocity oxyfuel spraying. Scanning electron microscopy observations revealed the accumulation of Tungsten-rich particles at the substrate-coating interface. These areas played an important role in the enhancement of the mechanical properties of the coating. The coating hardness increased 5 times with respect to the substrate one. The tribological analysis of the coating was done via pin on disk method. Results showed that abrasive wear is the dominant mechanism for the substrate; on the contrary, delamination is the dominant wear mechanism in the coating. The corrosion performance of bare and coated alloy was investigated by potentiodynamic polarization and electrochemical impedance spectroscopy. The corrosion potential of coated sample increases in comparison with bare alloy, corrosion current density decreases from 3.91 to 1.82 µA/cm2 and the capacitive resistance is much larger.
Graphic abstract
Similar content being viewed by others
Data availability
The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.
References
Y. Lv, L. Wang, Y. Han, X. Xu, W. Lu, Investigation of microstructure and mechanical properties of hot worked NiAl bronze alloy with different deformation degree. Mater. Sci. Eng. A 643, 17–24 (2015)
J.A. Wharton, R.C. Barik, G. Kear, R.J.K. Wood, K.R. Stokes, F.C. Walsh, The corrosion of nickel-aluminium bronze in seawater. Corros. Sci. 47, 3336–3367 (2005)
Q.N. Song, Y.G. Zheng, D.R. Ni, Z.Y. Ma, Characterization of the corrosion product films formed on the as-cast and friction-stir processed Ni-Al bronze in a 3.5 wt% NaCl solution. Corrosion 71, 606–614 (2015)
Q. Luo, Z. Wu, Z. Qin, L. Liu, W. Hu, Surface modification of nickel-aluminum bronze alloy with gradient Ni–Cu solid solution coating via thermal diffusion. Surf. Coat. Technol. 309, 106–113 (2017)
M. Islam, J. Ellor, et al. Corrosion (2015)
M. Koul, J. Gaies, An environmentally assisted cracking evaluation of UNS C64200 (Al–Si-Bronze) and UNS C63200 (Ni–Al-Bronze). J. Fail. Anal. Prev. 13, 8–19 (2013)
Q.N. Song, N. Xu, Y.F. Bao, Y.F. Jiang, W. Gu, Y.G. Zheng et al., Corrosion and cavitation erosion behaviors of two marine propeller materials in clean and sulfide-polluted 3.5% NaCl solutions. Acta Metall. Sin. (English Lett.) 30, 712–720 (2017)
K.-S. Park, S. Kim, Corrosion and corrosion fatigue characteristics of Cast NAB coated with NAB by HVOF thermal spray. J. Electrochem. Soc. 158, C335 (2011)
H.J. Li, D. Grudgings, N. Larkin, J. Norrish, M. Callaghan, L. Kuzmikova, Optimization of welding parameters for repairing NiAl bronze components. Mater. Sci. Forum 706–709, 2980–2985 (2012)
S. Sriintharasut, B. Poopat, I. Phung-On, The effects of different types of welding current on the characteristics of nickel aluminum bronze using gas metal arc welding. Mater. Today Proc. 5, 9535–9542 (2018)
P. Sassatelli, G. Bolelli, M. Lassinantti Gualtieri, E. Heinonen, M. Honkanen, L. Lusvarghi et al., Properties of HVOF-sprayed stellite-6 coatings. Surf. Coat. Technol. 338, 45–62 (2018)
A.K. Lakshminarayanan, V. Balasubramanian, R. Varahamoorthy, S. Babu, Predicting the dilution of plasma transferred arc hardfacing of stellite on carbon steel using response surface methodology. Met. Mater. Int. 14, 779–789 (2008)
M. Jafari, J. Mostaghimi, H. Monajatizadeh, M. Rafiei, Microstructure evaluation of CO-222/SiC coating produced by the plasma spraying method. Surf. Eng. 34, 220–225 (2018)
Š. Houdková, E. Smazalová, The influence of high temperature exposure on the wear of selected HVOF sprayed coatings. Defect Diffus. Forum 368, 55–58 (2016)
Y. Liu, W. Liu, Y. Ma, S. Meng, C. Liu, L. Long et al., A comparative study on wear and corrosion behaviour of HVOF- and HVAF-sprayed WC–10Co–4Cr coatings. Surf. Eng. 33, 63–71 (2017)
C. Navas, A. Conde, M. Cadenas, J. de Damborenea, Tribological properties of laser clad Stellite 6 coatings on steel substrates. Surf. Eng. 22, 26–34 (2006)
R. Arji, D.K. Dwivedi, S.R. Gupta, Sand slurry erosive wear of thermal sprayed coating of stellite. Surf. Eng. 23, 391–397 (2007)
C.R. Ciubotariu, D. Frunzəverde, G. Mərginean, V.A. Serban, A.V. Bîrdeanu, Optimization of the laser remelting process for HVOF-sprayed Stellite 6 wear resistant coatings. Opt. Laser Technol. 77, 98–103 (2016)
R. Shoja-Razavi, Laser surface treatment of stellite 6 coating deposited by HVOF on 316L alloy. J. Mater. Eng. Perform. 25, 2583–2595 (2016)
T.S. Sidhu, S. Prakash, R.D. Agrawal, Hot corrosion studies of HVOF NiCrBSi and stellite-6 coatings on a Ni-based superalloy in an actual industrial environment of a coal fired boiler. Surf. Coat. Technol. 201, 1602–1612 (2006)
D. Bartkowski, A. Młynarczak, A. Piasecki, B. Dudziak, M. Gos̈ciański, A. Bartkowska, Microstructure, microhardness and corrosion resistance of Stellite-6 coatings reinforced with WC particles using laser cladding. Opt. Laser Technol. 68, 191–201 (2015)
S. Apay, B. Gulenc, Wear properties of AISI 1015 steel coated with stellite 6 by microlaser welding. Mater. Des. 55, 1–8 (2014)
G. Lucchetta, R. Giusti, S. Vezzù, P.F. Bariani, Investigation and characterization of Stellite-based wear-resistant coatings applied to steel moulds by cold-spray. CIRP Ann. Manuf. Technol. 64, 535–538 (2015)
A. Kusmoko, D.P. Dunne, H. Li, A comparative study for wear resistant of stellite 6 coatings on nickel alloy substrate produced by laser cladding, HVOF and plasma spraying techniques. Int. J. Curr. Eng. Technol. 4, 32–36 (2014)
J.R. Davis et al., Handbook of Thermal Spray Technology (ASM International, Cleveland, 2004)
G.A. Jackson, M. Bai, Z. Pala, T. Hussain, W. Sun, Small punch creep testing of thermally sprayed Stellite 6 coating: a comparative study of as-received vs post-heat treatment. Mater. Sci. Eng. A 749, 137–147 (2019)
G. Kong, D. Zhang, P.D. Brown, D.G. McCartney, S.J. Harris, Microstructural characterisation of high velocity oxyfuel thermally sprayed Stellite 6. Mater. Sci. Technol. 19, 1003–1011 (2003)
O.C. Brandt, Mechanical properties of HVOF coatings. J. Therm. Spray Technol. 4, 147–152 (1995)
G.Y. Koga, W. Wolf, R. Schulz, S. Savoie, C. Bolfarini, C.S. Kiminami et al., Corrosion and wear properties of FeCrMnCoSi HVOF coatings. Surf. Coat. Technol. 357, 993–1003 (2019)
D. Rivera, R.E. Wirz, N.M. Ghoniem, Experimental measurements of surface damage and residual stresses in micro-engineered plasma facing materials. J. Nucl. Mater. 486, 111–121 (2017)
P. Araujo, D. Chicot, M. Staia, J. Lesage, Residual stresses and adhesion of thermal spray coatings. Surf. Eng. 21, 35–40 (2005)
M. Xie, Y. Lin, P. Ke, S. Wang, S. Zhang, Z. Zhen et al., Influence of process parameters on high velocity oxy-fuel sprayed Cr3C2–25%NiCr coatings. Coatings 7, 98 (2017)
S. Vignesh, K. Shanmugam, V. Balasubramanian, K. Sridhar, Identifying the optimal HVOF spray parameters to attain minimum porosity and maximum hardness in iron based amorphous metallic coatings. Def. Technol. 13, 101–110 (2017)
T.A. Dobbins, R. Knight, M.J. Mayo, X.K. Sun, Q.S. Wang, Y.B. Liu et al., HVOF thermal spray deposited Y2O3-stabilized ZrO2 coatings for thermal barrier applications. J. Therm. Spray Technol. 12, 214–225 (2003)
Z. Pala, M. Bai, F. Lukac, T. Hussain, Laser clad and HVOF-sprayed stellite 6 coating in chlorine-rich environment with KCl at 700 °C. Oxid. Met. 88, 749–771 (2017)
A.G.M. Pukasiewicz, H.E. de Boer, G.B. Sucharski, R.F. Vaz, L.A.J. Procopiak, The influence of HVOF spraying parameters on the microstructure, residual stress and cavitation resistance of FeMnCrSi coatings. Surf. Coat. Technol. 327, 158–166 (2017)
M. Vostřák, J. Tesař, Š. Houdková, E. Smazalová, M. Hruška, Diagnostic of laser remelting of HVOF sprayed Stellite coatings using an infrared camera. Surf. Coat. Technol. 318, 360–364 (2017)
R. Chattopadhyay, M. Park, Surface Wear: Analysis, Treatment, and Prevention (ASM International, Cleveland, 2001)
Q. Wang, S. Zhang, Y. Cheng, J. Xiang, X. Zhao, G. Yang, Wear and corrosion performance of WC-10Co4Cr coatings deposited by different HVOF and HVAF spraying processes. Surf. Coat. Technol. 218, 127–136 (2013)
S. Harsha, D.K. Dwivedi, Microstructure, hardness and abrasive wear behaviour of flame sprayed Co based alloy coating. Surf. Eng. 23, 261–266 (2007)
J. Hardell, A. Yousfi, M. Lund, L. Pelcastre, B. Prakash, Abrasive wear behaviour of hardened high strength boron steel. Tribol. Mater. Surf. Interfaces 8, 90–97 (2014)
V. Bonache, M.D. Salvador, J.C. García, E. Sánchez, E. Bannier, Influence of plasma intensity on wear and erosion resistance of conventional and nanometric WC-Co coatings deposited by APS. J. Therm. Spray Technol. 20, 549–559 (2011)
R.A. Seraj, A. Abdollah-zadeh, S. Dosta, H. Assadi, I.G. Cano, Comparison of stellite coatings on low carbon steel produced by CGS and HVOF spraying. Surf. Coat. Technol. 372, 299–311 (2019)
A.L. Ma, S.L. Jiang, Y.G. Zheng, W. Ke, Corrosion product film formed on the 90/10 copper-nickel tube in natural seawater: composition/structure and formation mechanism. Corros. Sci. 91, 245–261 (2015)
P.A. Sørensen, S. Kiil, K. Dam-Johansen, C.E. Weinell, Anticorrosive coatings: a review. J. Coat. Technol. Res. 6, 135–176 (2009)
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Mousavi, S.E., Naghshehkesh, N., Amirnejad, M. et al. Wear and Corrosion Properties of Stellite-6 Coating Fabricated by HVOF on Nickel–Aluminium Bronze Substrate. Met. Mater. Int. 27, 3269–3281 (2021). https://doi.org/10.1007/s12540-020-00697-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12540-020-00697-7