Thermal Barrier Coatings on Laser Surface Modified AISI H13 Tool Steel Using Atmospheric Plasma Spray Technique

Article Preview

Abstract:

This paper presents yttria-stabilized zirconia (YSZ) coating deposition on laser surface modified H13 tool steel using atmospheric plasma spray (APS) technique. A Praxair Plasma Spray System with SG-100 gun was used to deposit coating materials on laser-modified H13 tool steel substrate surface. A bond coat layer material was NiCrAlY alloy while the top coat was yttria stabilized zirconia (YSZ) with powder size distribution range of-106 μm to +45 μm. A 23 design of experiment (DOE) was used to deposit bond coat and top coat powders with three controlled factors of input current, powder feed rate and stand-off-distance. The design was optimised for minimum porosity and maximum hardness. The coating thickness and percentage of porosity were measured using IM7000 inverted optical microscope. Hardness properties of top coating layer were measured by using MMT-X7 Matsuzawa Hardness Tester Machine with Vickers hardness scale. The microscopy findings indicated variations of coating thickness at different parameters settings. Samples at the highest current and powder feed rate and lowest stand-off distance settings produced a lower porosity percentage and higher hardness. A higher powder feed rate with the smallest stand-off-distance allowed melted powders to travel uniformly onto the substrate surface. These findings were significant to development of thermal barrier coatings on semi-solid forming die surface.

You might also be interested in these eBooks

Info:

Periodical:

Key Engineering Materials (Volumes 554-557)

Pages:

603-610

Citation:

Online since:

June 2013

Export:

Price:

[1] Amit Srivastava, Vivek Joshi, Rajiv Shivpuri, Rabi Bhattacharya, Satish Dixit, A multilayer coating architecture to reduce heat checking of die surfaces, Surface and Coatings Technology, Volumes 163–164, 30 January 2003, Pages 631-636, ISSN 0257-8972.

DOI: 10.1016/S0257-8972(02)00690-4

Google Scholar

[2] L.J.D. Sully, in Metals Handbook, 9th ed., vol. 15, ASM International, Metals Park, Ohio, 1988 p.286.

Google Scholar

[3] J.R. Davis (Ed.), in ASM Specialty Handbook, Tool Materials, ASM International, Materials Park, Ohio, 1995, p.251.

Google Scholar

[4] D.F. Allsop, D. Kennedy, in Pressure diecasting, Part 2: The technology of the casting and the die, Pergamon Press Ltd, Oxford, 1983.

Google Scholar

[5] J.R. Davis, Introduction to thermal spray processing, in Handbook of Thermal Spray Technologies, ASM International, Materials Park, OH, p.3–9, 2004.

Google Scholar

[6] R.C. Tucker, Jr., Thermal Spray Coatings, in Surface Engineering, Vol 5, ASM Handbook, ASM International, 1994, p.497–509.

Google Scholar

[7] A. Abdellah El-Hadj, M. Zirari, N. Bacha, Numerical analysis of the effect of the gas temperature on splat formation during thermal spray process, Applied Surface Science, Volume 257, Issue 5, 15 December 2010, Pages 1643-1648, ISSN 0169-4332.

DOI: 10.1016/j.apsusc.2010.08.115

Google Scholar

[8] C.J. Li, A. Ohmori, Relationships between the microstructure and properties of thermally sprayed deposits, J. Therm. Spray Technol., 11 (2002), pp.365-374.

DOI: 10.1361/105996302770348754

Google Scholar

[9] L. Wang, J.C. Fang, Z.Y. Zhao, H.P. Zeng, Application of backward propagation network for forecasting hardness and porosity of coatings by plasma spraying, Surface and Coatings Technology, 201 (2007), p.5085–5089

DOI: 10.1016/j.surfcoat.2006.07.088

Google Scholar

[10] X.C. Zhang, B.S. Xu, F.Z. Xuan, H.D. Wang, Y.X. Wu, S.T. Tu, Statistical analyses of porosity variations in plasma-sprayed Ni-based coatings, Journal of Alloys and Compounds, 467 (2009), p.501–508

DOI: 10.1016/j.jallcom.2007.12.083

Google Scholar

[11] S. Deshpande, A. Kulkarni, S. Sampath, H. Herman, Application of image analysis for characterization of porosity in thermal spray coatings and correlation with small angle neutron scattering, Surface and Coatings Technology, 187 (2004), p.6–16

DOI: 10.1016/j.surfcoat.2004.01.032

Google Scholar

[12] R. Venkataraman, G. Dasa, S.R. Singh, L.C. Pathak, R.N. Ghosha, B. Venkataraman, R. Krishnamurthy, Study on influence of porosity, pore size, spatial and topological distribution of pores on micro-hardness of as plasma sprayed ceramic coatings, Materials Science and Engineering, 445 (2007), p.269–274

DOI: 10.1016/j.msea.2006.09.042

Google Scholar

[13] S. Guessasma, C. Coddet, Neural computation applied to APS spray process: porosity analysis, Surface and Coatings Technology, 197 (2005), p.85–92

DOI: 10.1016/j.surfcoat.2005.01.124

Google Scholar

[14] de Lovelock HL, Villers RPW, Benson JM, Young PM (1998) Parameter study of HP/HVOF deposited WC-Co coatings. J Thermal Spray Technol 7(1):97–107.

DOI: 10.1007/s11666-006-5010-x

Google Scholar

[15] Kingswell R, Scott KT, Wassell LL (1993) Optimizing the vacuum plasma spray deposition of metal, ceramic, and cermet coatings using designed experiments. J Thermal Spray Technol 2(2):179–186.

DOI: 10.1007/bf02652027

Google Scholar

[16] Burlacov I, Jirkovsky J, Muller M, Heimann RB (2006) Induction plasma-sprayed photocatalytically active titania coatings and their characterization by micro-Raman spectroscopy. Surf Coat Technol 201:255–264.

DOI: 10.1016/j.surfcoat.2005.11.117

Google Scholar

[17] R. Venkataraman, G. Dasa, S.R. Singh, L.C. Pathak, R.N. Ghosha, B. Venkataraman, R. Krishnamurthy, Study on influence of porosity, pore size, spatial and topological distribution of pores on micro-hardness of as plasma sprayed ceramic coatings, Materials Science and Engineering, 445 (2007), p.269–274

DOI: 10.1016/j.msea.2006.09.042

Google Scholar

[18] I.Yu. Konyashin, T.V. Chukalovskaya, A technique for measurement of porosity in protective coatings, Surface and Coatings Technology, 88 (1996), p.5–11

DOI: 10.1016/s0257-8972(95)02758-0

Google Scholar

[19] Hao Du, Soo Wohn Lee, Jae Heyg Shin, Study on porosity of plasma-sprayed coatings by digital image analysis method, Journal of Thermal Spray Technology, 14 (2005), p.453–461

DOI: 10.1361/105996305x76450

Google Scholar