Enhanced Surface Protection: Microwave-Assisted Metallic Cladding of Ni-ZrO2 Mixture onto SS-304

Abstract

This study focuses on enhancing surface protection through microwave-assisted metallic cladding of a Ni-ZrO2 mixture onto SS-304 substrates. Meticulous preparation steps ensured effective deposition: SS-304 underwent thorough cleaning, while the Ni-ZrO2 mixture was preheated to remove moisture. Maintaining uniform distribution was crucial for consistent coating thickness. Microwaves interacted differently with materials, necessitating consideration of material-specific skin depth to avoid direct particle-microwave interaction. Microwave hybrid heating (MHH) with charcoal as a susceptor overcame microwave reflection, facilitating rapid heating of the powder mixture. A pure graphite sheet prevented contamination during MHH. Subsequent irradiation in a multimode microwave applicator for 120 seconds ensured uniform and controlled heating, as illustrated in Figure 1. SEM analysis revealed the distribution and morphology of Ni and ZrO2 particles on the SS-304 surface, indicating effective deposition and adherence. A significant improvement in surface hardness (40.78%) post-cladding was observed. Furthermore, the wear rate and coefficient of friction of the cladded surface were determined to be 0.00124 mm3/m and 0.243, respectively. These findings highlight the promising tribological performance of the Ni-ZrO2 cladded surface, underscoring its potential for applications requiring enhanced surface protection and improved mechanical properties.