Comparative Study on the Cavitation Erosion and Sliding Wear of Cold-Sprayed Al/Al2O3 and Cu/Al2O3 Coatings, and Stainless Steel, Aluminium Alloy, Copper and Brass

Abstract

The paper investigates the cavitation erosion (CE) and sliding wear (SW) resistance of cold-sprayed Al/Al2O3 and Cu/Al2O3 composites and studies them in relation to a set of metallic materials such as aluminium alloy (AlCu4Mg1), pure copper (Cu110), brass (CuZn40Pb2) and stainless steel (AISI 304). The coatings were deposited on stainless steel by low-pressure cold spray (LPCS) using Al (40 wt.%) and Cu (50 wt.%) blended with Al2O3 (60 and 50 wt.%, respectively) feedstocks. CE resistance was estimated by the stationary sample method according to the ASTM G32 standard. The SW test was conducted using a ball-on-disc tester with compliance to the ASTM G99 standard. Results obtained for the LPCS coatings show that the Cu/Al2O3 coating exhibits a denser structure but lower adhesion and microhardness than Al/Al2O3. The Al/Al2O3 and Cu/Al2O3 resistance to cavitation is lower than for bulk alloys; however, composites present higher sliding wear resistance to that of AlCu4Mg1, CuZn40Pb2 and stainless steel. The CE wear mechanisms of LPCS composites start at the structural discontinuities and non-uniformities. The cavitation erosion degradation mechanism of Al/Al2O3 relies on chunk material detachment while that of Cu/Al2O3 initiates by alumina removal and continues as layer-like Cu-metallic material removal. CE damage of metal alloys relies on the fatigue-induced removal of deformed material. The SW mechanism of bulk alloys has a dominant adhesive mode. The addition of Al2O3 successfully reduces the material loss of LPCS composites but increases the friction coefficient. Coatings’ wear mechanism has an adhesive-abrasive mode. In both CE and SW environment, the behaviour of the cold-sprayed Cu/Al2O3 composite is much more promising than that of the Al/Al2O3.

Laser Dissimilar Welding of AISI 430F and AISI 304 Stainless Steels

“…The development of technology is aimed at reducing production and operating costs, increasing the safety of use and improving ecology in the context of the development of materials. This opens the possibility of using new materials, developing the existing ones and modifying their properties [ 1 ]. Particularly in the area of welded joints, especially dissimilar joints, there are many opportunities due to the multitude of materials, processes and additional treatments that can significantly affect the final product.…”

Tribological Behaviour of K340 Steel PVD Coated with CrAlSiN Versus Popular Tool Steel Grades

“…This effect is the most noticeable in the wear track obtained for the X155CrVMo12-1 steel with the lowest wear resistance. Comparable material-deterioration morphology in the wear track, characterised by severe adhesive wear mode, was also observed for untreated Al-, and Cu-based metal alloys tested at ambient temperature under dry sliding [46]. (Figure 7).…”

Mechanical Properties and Sliding Wear Resistance of Suspension Plasma Sprayed YSZ Coatings

“…Summing up, the results given in Table 3 indicate a relatively high wear resistance of both YSZ coatings. In comparison to the recent results reported by our research group [39][40][41][42][43][44][45] for metallic materials, coatings and surface treatments, the overall wear resistance of the YSZ coatings can be classified as comparable to the alumina-based ceramic coating, rather than bulk metal alloys, composite coatings or metallic coatings. On the other hand, it is to be mentioned that similar results were obtained for typically submicrometric coatings, also with yttria stabilised zirconia oxide as the output material, but with the grain size c.a.…”