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Effect of Coating Thickness on Fatigue Behavior of AISI 1045 Steel with HVOF Thermal Spray and Hard Chrome Electroplating

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Abstract

The effects of coating thickness on the fatigue lives of AISI 1045 steel shaft-bending specimens with WC-10%Co-4%Cr high-velocity oxygen fuel (HVOF) coatings and hard chrome electroplated coatings under cyclic loading conditions are investigated. Residual stress distributions of the HVOF-coated layer and the hard chrome-plated layer were measured. During cyclic fatigue testing, cracks are initiated near the interface between the HVOF coating and the steel substrate and propagate through the substrate to cause final fracture based on experimental results. For the specimens with hard chrome-plated coatings, the fatigue crack is initiated near the top of the coating, propagates through the coating, and then grows in the thickness direction of the steel substrate to cause final fracture. As the coating thickness of the HVOF-coated specimens increases, the fatigue strength of the specimens increases, which can be attributed to the fact that the magnitude of the compressive residual stress near the interface between the substrates and the HVOF coatings is higher when the coating thickness gets higher. As for the hard chrome-plated specimens, the fatigue strength is deteriorated when the coating thickness is increased. The microcrack density in the hard chrome coatings increases with the coating thickness and, therefore, may result in the decreased fatigue strength.

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Acknowledgement

The authors would like to express their appreciation to the staff of Ho Chi Minh City Center for Nuclear Techniques and the Metallurgy Laboratory at Ho Chi Minh City University of Technology and Education for their assistance. Helpful discussions with Dr. Huy Dong Pham of An Binh Coating Corporation are greatly appreciated.

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Authors and Affiliations

  1. HCM City University of Technology and Education, Hochiminh City, Vietnam

    Vinh Phoi Nguyen, Thien Ngon Dang & Chi Cuong Le

  2. Graduate Institute of Precision Engineering, National Chung Hsing University, Taichung, Taiwan

    Dung-An Wang

  3. Faculty of Mechanical Engineering, Industrial University of Ho Chi Minh City, Ho Chi Minh City, Vietnam

    Dung-An Wang

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Nguyen, V.P., Dang, T.N., Le, C.C. et al. Effect of Coating Thickness on Fatigue Behavior of AISI 1045 Steel with HVOF Thermal Spray and Hard Chrome Electroplating. J Therm Spray Tech 29, 1968–1981 (2020). https://doi.org/10.1007/s11666-020-01090-x

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