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THE STUDY OF CHARACTERISTICS OF ELASTICITY AND RESIDUAL STRESSES IN COATINGS APPLIED BY PLASMA METHODS
Authors:
Igor Kravchenko1,2, Ivan Kartsev1, Sergey Kartsev1, Sergey Velichko3, Yury Kuznetsov4
Denis Prokhorov4, Aleksandar Ašonja5, Larisa Kalashnikova6
1Institute of Mechanical Engineering of the Russian Academy of Sciences named after A.A. Blagonravov (IMASH RAS), Moscow, Russia
2Russian State Agrarian University – MTAA named after K.A. Timiryazev, Moscow, Russia
3National Research Mordovia State University named after N.P. Ogarev, Saransk, Russia
4Orel State Agrarian University named after N.V. Parakhin, Orel, Russia
5Faculty of Economics and Engineering Management in Novi Sad, University Business Academy in Novi Sad,Serbia
6Orel State University named after I.S. Turgenev, Orel, Russia
Received: 24.01.2022.
Accepted: 10.03.2022.
Available: 31.03.2022.
Abstract:
At present, a strategically important task of technological independence of Russian industries is restoration of worn-out parts of machines and equipment by plasma methods based on the use of coatings of different functional purpose. The purpose of this study is to solve the actual problem of choosing the rational modes of plasma coating in the process of restoration of worn parts, subjected to intensive wear in the operation process. To solve this problem, the experimental studies of the elasticity characteristics in the plasma-deposited coatings were carried out. The study results allowed determining the most optimal range of rational modes of plasma coating deposition in terms of obtaining high elastic properties of plasma coatings as the key stage of resource-saving technology for restoration of worn parts of machinery and equipment.
Keywords:
Plasma surfacing, Plasmatron, Fatigue resistance, Deformation curve, Fusion zone
References:
[1] S.A. Sidorov, D.A. Mironov, V.K. Khoroshenkov, E.I. Khlusova, Surfacing methods for increasing the service life of rapidly wearing working tools of agricultural machines. Welding International, 30(10), 2016: 808-812.
https://doi.org/10.1080/09507116.2016.1148408
[2] B. Huang, Ch. Zhang, G. Zhang, H. Liao, Wear and corrosion resistant performance of thermal-sprayed Fe-based amorphous coatings: A review. Surface and Coatings Technology, 377, 2019: 124896.
https://doi.org/10.1016/j.surfcoat.2019.124896
[3] M. AE. Hafez, S.A. Akila, M.A. Khedr, A.S. Khalil, Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure. Scientific Reports, 10, 2020:21830. https://doi.org/10.1038/s41598-020-78088-6
[4] G. Mauer, M.O. Jarligo, D.E. Mack, R. Vaßen, Plasma-sprayed thermal barrier coatings: new materials, processing issues, and solutions, Journal of Thermal Spray Technology, 22(5), 2013: 646-658. https://doi.org/10.1007/s11666-013-9889-8
[5] V. Alisin, R.N. Roshchin, Thermal plasma spray to protect large-size parts of friction joints against wear. Solid State Phenomena, 316, 2021: 770-776. https://doi.org/10.4028/www.scientific.net/SSP.316.770
[6] P.V. Gladkii, E.F. Perepletchikov, I.A. Ryabtsev, Plasma surfacing. Welding International, 21(9), 2007: 685-693. https://doi.org/10.1080/09507110701631141
[7] O. N. Çelik, Microstructure and wear properties of WC particle reinforced composite coating on Ti6Al4V alloy produced by the plasma transferred arc method. Applied Surface Science, 274(6), 2013: 334-340.
https://doi.org/10.1016/j.apsusc.2013.03.057
[8] Yi. Wei, Xian-sh. Wei, B. Chen, Ji.-yo. Zuo, Tian cai. Ma, Jun Shen, Parameter optimization for tungsten carbide/Ni-based composite coating deposited by plasma transferred arc hardfacing. Transactions of Nonferrous Metals Society of China, 28(12), 2018: 2511-2519. https://doi.org/10.1016/S1003-6326(18)64897-6
[9] L.-M. Berger, Application of hardmetals as thermal spray coatings. International Journal of Refractory Metals and Hard Materials, 49(3), 2015: 350-364. https://doi.org/10.1016/j.ijrmhm.2014.09.029
[10] P. Fauchais, G. Montavon, G. Bertrand, From powders to thermally sprayed coatings. Journal of Thermal Spray Technology, 19, 2010: 56-80. https://doi.org/10.1007/s11666-009-9435-x
[11] S.M. Muneer, M. Nadeera, Wear characterization and microstructure evaluation of silicon carbide based nano composite coating using plasma spraying. Materials Today: Proceedings, 5(11), part 3, 2018: 23834-23843.
https://doi.org/10.1016/j.matpr.2018.10.175
[12] Zh. Gan, Heong W. Ng, Ap. Devasenapathi, Deposition-induced residual stresses in plasma-sprayed coatings. Surface and Coatings Technology, 187(2-3), 2004: 307-319. https://doi.org/10.1016/j.surfcoat.2004.02.010
[13] W. Tillmann, L. Hagen, W. Luo, Process parameter settings and their effect on residual stresses in WC/W2C reinforced iron-based arc sprayed coatings. Coatings, 7(8), 2017: 125. https://doi.org/10.3390/coatings7080125
[14] S.-W. Yao, J.-J. Tian, C.-J. Li, G.-J. Yang, C.-X. Li, Understanding the formation of limited interlamellar bonding in plasma sprayed ceramic coatings cased on the concept of intrinsic bonding temperature. Journal of Thermal Spray Technology, 25(8), 2016: 1617-1630. https://doi.org/10.1007/s11666-016-0464-y
[15] I.N. Kravchenko, S.V. Kartsev, Yu.A. Kuznetsov, S. A. Velichko, Optimization of plasma deposition and coating plasma fusion parameters and regimes. Refractories and Industrial Ceramics, 62(1), 2021: 51-56. https://doi.org/10.1007/s11148-021-00557-w
[16] I.N. Kravchenko, S.V. Kartsev, Yu.A. Kuznetsov, Use of hot hydrocarbons in a plasma installation for application of wear-resistant coating. Refractories and Industrial Ceramics, 61(4), 2020: 399-403. https://doi.org/10.1007/s11148-020-00492-2
[17] G. Dwivedi, T. Wentz, S. Sampath, T. Nakamura, Assessing process and coating reliability through monitoring of process and design relevant coating properties. Journal of Thermal Spray Technology, 19(6), 2010: 695-712. https://doi.org/10.1007/s11666-009-9467-2
[18] D. Chicot, H. Ageorges, M. Voda, G. Louis, M.A. Ben Dhia, C.C. Palacio, S.Kossman, Hardness of thermal sprayed coatings: Relevance of the scale of measurement. Surface and Coatings Technology, 268(4), 2015: 173-179. https://doi.org/10.1016/j.surfcoat.2014.04.043
[19] O.P. Solonenko, V.I. Jordan, V.A. Blednov, Stochastic computer simulation of cermet coatings formation. Advances in Materials Science and Engineering, 2015: 396427. https://doi.org/10.1155/2015/396427
[20] В.A. Okovitiy, F.I. Panteleenko, V.V. Okovitiy, V.M. Astashinsky, Optimization of the process of coating deposition of metal-ceramic powders by plasma spraying in air. Science and Technology, 20(5), 2021: 369-374. https://doi.org/10.21122/2227-1031-2021-20-5-369-374
[21] I. Ahmed, T.L. Bergman, Optimization of plasma spray processing parameters for deposition of nanostructured powders for coating formation. Journal of Fluids Engineering, 128(2), 2006: 394-401. https://doi.org/10.1115/1.2170131
[22] D. Thirumalaikumarasamy, V. Dalasubramanian, S. Sree Sabari, Prediction and optimization of process variables to maximize the Young’s modulus of plasma sprayed alumina coatings on AZ31B magnesium alloy. Journal of Magnesium and Alloys, 5(1), 2017: 133-145. https://doi.org/10.1016/j.jma.2017.02.002
[23] J. H. You, T. Höschen, S. Lindig, Determination of elastic modulus and residual stress of plasma-sprayed tungsten coating on steel substrate. Journal of Nuclear Materials, 348(1-2), 2006: 94-101.
https://doi.org/10.1016/j.jnucmat.2005.09.015
[24] W.C. Oliver, G.M. Pharr, Measurement of hardness and elastic modulus by instrumented indentation: Advances in understanding and refinements to methodology. Journal of Materials Research, 19(1), 2004: 3-20.
https://doi.org/10.1557/jmr.2004.19.1.3
[25] А.В. Vakhrushev, A.A. Pushkov, S.N. Zykov, and V.S. Klekovkin, Determination of the Young modulus of nanoparticles based on numerical simulation and experimental studies. P.1. Methodological foundations of numerical simulations. Chemical Physics and Mesoscopy, 16(3), 2014: 381-387.
[26] R.C. Batra, U. Taetragool, Numerical techniques to find optimal input parameters for achieving mean particles’ temperature and axial velocity in atmospheric plasma spray process. Scientific Reports, 10, 2020: 21483.
https://doi.org/10.1038/s41598-020-78424-w
[27] M. A. Ageev, T.V. Vigerina, K.A. Danko, S.A. Dovzhuk, S.L. Chigray, A.V. Lopata, Assessment of influence of parameters of gas-thermal spraying of coatings on their properties by using mathematical planning methods. Bulletin of Polotsk State University. Series V. Industry. Applied Sciences, 3, 2017: 35-40.
[28] I.N. Kravchenko, S.V. Kartsev, A.V. Kolomeichenko, Yu.A. Kuznetsov, S.N. Perevislov, М.А. Markov, Metallurgical features of plasma surfacing with powder hard alloy with addition of aluminum powder. Metallurgist, 64(9-10), 2021: 1077-1085. https://doi.org/10.1007/s11015-021-01089-x
[29] С.V. Kartsev, Mathematical model of optimization of controllable parameters of the technological process of plasma surfacing of wear-resistant coatings. Problems of Mechanical Engineering and Automation, 2, 2020: 50-55.
[30] B.E. Vasilyev, М.Е. Volkov, Е.N. Bredihina, I.I. Pleshcheev, Plotting of calculated deformation curves to provide a data bank on the structural strength of aircraft engine materials. Materials Physics and Mechanics, 42(5), 2019: 656-670.
[31] MMPDS-11: Metallic materials properties development and standardization (MMPDS). Battelle Memorial Institute, 2016.
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 10
Number 1
March 2025
Last Edition
Volume 10
Number 1
March 2025
How to Cite
I. Kravchenko, I. Kartsev, S. Kartsev, S. Velichko, Y. Kuznetsov, D.Prokhorov, A. Ašonja, L. Kalashnikova, The Study of Characteristics of Elasticity and Residual Stresses in Coatings Applied by Plasma Methods. Applied Engineering Letters, 7(1), 2022: 25-31.
https://doi.org/10.18485/aeletters.2022.7.1.4
More Citation Formats
Kravchenko, I., Kartsev, I., Kartsev, S., Velichko, S., Kuznetsov, Y., Prokhorov, D., Ašonja, A., & Kalashnikova, L. (2022). The Study of Characteristics of Elasticity and Residual Stresses in Coatings Applied by Plasma Methods. Applied Engineering Letters, 7(1), 25-31. https://doi.org/10.18485/aeletters.2022.7.1.4
Kravchenko, Igor, et al. “The Study of Characteristics of Elasticity and Residual Stresses in Coatings Applied by Plasma Methods.” Applied Engineering Letters, vol. 7, no. 1, 2022, pp. 25-31, https://doi.org/10.18485/aeletters.2022.7.1.4.
Kravchenko, Igor, Ivan Kartsev, Sergey Kartsev, Sergey Velichko, Yury Kuznetsov, Denis Prokhorov, Aleksandar Ašonja, and Larisa Kalashnikova. 2022. “The Study of Characteristics of Elasticity and Residual Stresses in Coatings Applied by Plasma Methods.” Applied Engineering Letters 7 (1): 25-31. https://doi.org/10.18485/aeletters.2022.7.1.4.
Kravchenko, I., Kartsev, I., Kartsev, S., Velichko, S., Kuznetsov, Y., Prokhorov, D., Ašonja, A. and Kalashnikova, L. (2022). The Study of Characteristics of Elasticity and Residual Stresses in Coatings Applied by Plasma Methods. Applied Engineering Letters, 7(1), pp.25-31.
doi: 10.18485/aeletters.2022.7.1.4.
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THE STUDY OF CHARACTERISTICS OF ELASTICITY AND RESIDUAL STRESSES IN COATINGS APPLIED BY PLASMA METHODS
Authors:
Igor Kravchenko1,2, Ivan Kartsev1, Sergey Kartsev1, Sergey Velichko3, Yury Kuznetsov4
Denis Prokhorov4, Aleksandar Ašonja5, Larisa Kalashnikova6
1Institute of Mechanical Engineering of the Russian Academy of Sciences named after A.A. Blagonravov (IMASH RAS), Moscow, Russia
2Russian State Agrarian University – MTAA named after K.A. Timiryazev, Moscow, Russia
3National Research Mordovia State University named after N.P. Ogarev, Saransk, Russia
4Orel State Agrarian University named after N.V. Parakhin, Orel, Russia
5Faculty of Economics and Engineering Management in Novi Sad, University Business Academy in Novi Sad,Serbia
6Orel State University named after I.S. Turgenev, Orel, Russia
Received: 24.01.2022.
Accepted: 10.03.2022.
Available: 31.03.2022.
Abstract:
At present, a strategically important task of technological independence of Russian industries is restoration of worn-out parts of machines and equipment by plasma methods based on the use of coatings of different functional purpose. The purpose of this study is to solve the actual problem of choosing the rational modes of plasma coating in the process of restoration of worn parts, subjected to intensive wear in the operation process. To solve this problem, the experimental studies of the elasticity characteristics in the plasma-deposited coatings were carried out. The study results allowed determining the most optimal range of rational modes of plasma coating deposition in terms of obtaining high elastic properties of plasma coatings as the key stage of resource-saving technology for restoration of worn parts of machinery and equipment.
Keywords:
Plasma surfacing, Plasmatron, Fatigue resistance, Deformation curve, Fusion zone
References:
[1] S.A. Sidorov, D.A. Mironov, V.K. Khoroshenkov, E.I. Khlusova, Surfacing methods for increasing the service life of rapidly wearing working tools of agricultural machines. Welding International, 30(10), 2016: 808-812. https://doi.org/10.1080/09507116.2016.1148408
[2] B. Huang, Ch. Zhang, G. Zhang, H. Liao, Wear and corrosion resistant performance of thermal-sprayed Fe-based amorphous coatings: A review. Surface and Coatings Technology, 377, 2019: 124896. https://doi.org/10.1016/j.surfcoat.2019.124896
[3] M. AE. Hafez, S.A. Akila, M.A. Khedr, A.S. Khalil, Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure. Scientific Reports, 10, 2020:21830. https://doi.org/10.1038/s41598-020-78088-6
[4] G. Mauer, M.O. Jarligo, D.E. Mack, R. Vaßen, Plasma-sprayed thermal barrier coatings: new materials, processing issues, and solutions, Journal of Thermal Spray Technology, 22(5), 2013: 646-658. https://doi.org/10.1007/s11666-013-9889-8
[5] V. Alisin, R.N. Roshchin, Thermal plasma spray to protect large-size parts of friction joints against wear. Solid State Phenomena, 316, 2021: 770-776. https://doi.org/10.4028/www.scientific.net/SSP.316.770
[6] P.V. Gladkii, E.F. Perepletchikov, I.A. Ryabtsev, Plasma surfacing. Welding International, 21(9), 2007: 685-693. https://doi.org/10.1080/09507110701631141
[7] O. N. Çelik, Microstructure and wear properties of WC particle reinforced composite coating on Ti6Al4V alloy produced by the plasma transferred arc method. Applied Surface Science, 274(6), 2013: 334-340. https://doi.org/10.1016/j.apsusc.2013.03.057
[8] Yi. Wei, Xian-sh. Wei, B. Chen, Ji.-yo. Zuo, Tian cai. Ma, Jun Shen, Parameter optimization for tungsten carbide/Ni-based composite coating deposited by plasma transferred arc hardfacing. Transactions of Nonferrous Metals Society of China, 28(12), 2018: 2511-2519. https://doi.org/10.1016/S1003-6326(18)64897-6
[9] L.-M. Berger, Application of hardmetals as thermal spray coatings. International Journal of Refractory Metals and Hard Materials, 49(3), 2015: 350-364. https://doi.org/10.1016/j.ijrmhm.2014.09.029
[10] P. Fauchais, G. Montavon, G. Bertrand, From powders to thermally sprayed coatings. Journal of Thermal Spray Technology, 19, 2010: 56-80. https://doi.org/10.1007/s11666-009-9435-x
[11] S.M. Muneer, M. Nadeera, Wear characterization and microstructure evaluation of silicon carbide based nano composite coating using plasma spraying. Materials Today: Proceedings, 5(11), part 3, 2018: 23834-23843. https://doi.org/10.1016/j.matpr.2018.10.175
[12] Zh. Gan, Heong W. Ng, Ap. Devasenapathi, Deposition-induced residual stresses in plasma-sprayed coatings. Surface and Coatings Technology, 187(2-3), 2004: 307-319. https://doi.org/10.1016/j.surfcoat.2004.02.010
[13] W. Tillmann, L. Hagen, W. Luo, Process parameter settings and their effect on residual stresses in WC/W2C reinforced iron-based arc sprayed coatings. Coatings, 7(8), 2017: 125. https://doi.org/10.3390/coatings7080125
[14] S.-W. Yao, J.-J. Tian, C.-J. Li, G.-J. Yang, C.-X. Li, Understanding the formation of limited interlamellar bonding in plasma sprayed ceramic coatings cased on the concept of intrinsic bonding temperature. Journal of Thermal Spray Technology, 25(8), 2016: 1617-1630. https://doi.org/10.1007/s11666-016-0464-y
[15] I.N. Kravchenko, S.V. Kartsev, Yu.A. Kuznetsov, S. A. Velichko, Optimization of plasma deposition and coating plasma fusion parameters and regimes. Refractories and Industrial Ceramics, 62(1), 2021: 51-56. https://doi.org/10.1007/s11148-021-00557-w
[16] I.N. Kravchenko, S.V. Kartsev, Yu.A. Kuznetsov, Use of hot hydrocarbons in a plasma installation for application of wear-resistant coating. Refractories and Industrial Ceramics, 61(4), 2020: 399-403. https://doi.org/10.1007/s11148-020-00492-2
[17] G. Dwivedi, T. Wentz, S. Sampath, T. Nakamura, Assessing process and coating reliability through monitoring of process and design relevant coating properties. Journal of Thermal Spray Technology, 19(6), 2010: 695-712. https://doi.org/10.1007/s11666-009-9467-2
[18] D. Chicot, H. Ageorges, M. Voda, G. Louis, M.A. Ben Dhia, C.C. Palacio, S.Kossman, Hardness of thermal sprayed coatings: Relevance of the scale of measurement. Surface and Coatings Technology, 268(4), 2015: 173-179. https://doi.org/10.1016/j.surfcoat.2014.04.043
[19] O.P. Solonenko, V.I. Jordan, V.A. Blednov, Stochastic computer simulation of cermet coatings formation. Advances in Materials Science and Engineering, 2015: 396427. https://doi.org/10.1155/2015/396427
[20] В.A. Okovitiy, F.I. Panteleenko, V.V. Okovitiy, V.M. Astashinsky, Optimization of the process of coating deposition of metal-ceramic powders by plasma spraying in air. Science and Technology, 20(5), 2021: 369-374. https://doi.org/10.21122/2227-1031-2021-20-5-369-374
[21] I. Ahmed, T.L. Bergman, Optimization of plasma spray processing parameters for deposition of nanostructured powders for coating formation. Journal of Fluids Engineering, 128(2), 2006: 394-401. https://doi.org/10.1115/1.2170131
[22] D. Thirumalaikumarasamy, V. Dalasubramanian, S. Sree Sabari, Prediction and optimization of process variables to maximize the Young’s modulus of plasma sprayed alumina coatings on AZ31B magnesium alloy. Journal of Magnesium and Alloys, 5(1), 2017: 133-145. https://doi.org/10.1016/j.jma.2017.02.002
[23] J. H. You, T. Höschen, S. Lindig, Determination of elastic modulus and residual stress of plasma-sprayed tungsten coating on steel substrate. Journal of Nuclear Materials, 348(1-2), 2006: 94-101. https://doi.org/10.1016/j.jnucmat.2005.09.015
[24] W.C. Oliver, G.M. Pharr, Measurement of hardness and elastic modulus by instrumented indentation: Advances in understanding and refinements to methodology. Journal of Materials Research, 19(1), 2004: 3-20. https://doi.org/10.1557/jmr.2004.19.1.3
[25] А.В. Vakhrushev, A.A. Pushkov, S.N. Zykov, and V.S. Klekovkin, Determination of the Young modulus of nanoparticles based on numerical simulation and experimental studies. P.1. Methodological foundations of numerical simulations. Chemical Physics and Mesoscopy, 16(3), 2014: 381-387.
[26] R.C. Batra, U. Taetragool, Numerical techniques to find optimal input parameters for achieving mean particles’ temperature and axial velocity in atmospheric plasma spray process. Scientific Reports, 10, 2020: 21483. https://doi.org/10.1038/s41598-020-78424-w
[27] M. A. Ageev, T.V. Vigerina, K.A. Danko, S.A. Dovzhuk, S.L. Chigray, A.V. Lopata, Assessment of influence of parameters of gas-thermal spraying of coatings on their properties by using mathematical planning methods. Bulletin of Polotsk State University. Series V. Industry. Applied Sciences, 3, 2017: 35-40.
[28] I.N. Kravchenko, S.V. Kartsev, A.V. Kolomeichenko, Yu.A. Kuznetsov, S.N. Perevislov, М.А. Markov, Metallurgical features of plasma surfacing with powder hard alloy with addition of aluminum powder. Metallurgist, 64(9-10), 2021: 1077-1085. https://doi.org/10.1007/s11015-021-01089-x
[29] С.V. Kartsev, Mathematical model of optimization of controllable parameters of the technological process of plasma surfacing of wear-resistant coatings. Problems of Mechanical Engineering and Automation, 2, 2020: 50-55.
[30] B.E. Vasilyev, М.Е. Volkov, Е.N. Bredihina, I.I. Pleshcheev, Plotting of calculated deformation curves to provide a data bank on the structural strength of aircraft engine materials. Materials Physics and Mechanics, 42(5), 2019: 656-670.
[31] MMPDS-11: Metallic materials properties development and standardization (MMPDS). Battelle Memorial Institute, 2016.
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 10
Number 1
March 2025
Last Edition
Volume 10
Number 1
March 2025