HIGH DENSITY INFRARED PROCESSING OF WC/Ni–11P COMPOSITE COATINGS

Abstract

A new high density infrared based coating process has been developed to produce wear resistant coatings on AISI 4340 steel substrates that are of commercial interest. The process combines infrared heating, with power densities up to 35 MW m -2, with room temperature precursor spray deposition processes to rapidly form wear resistant coatings. Here, the process is demonstrated using a 20 vol.-%WC reinforced coating in a Ni-11 wt-%P binder on a AISI 4340 steel substrate, to produce a smooth, high density, 10 μm thick coating with minimal degradation of the WC reinforcement or base steel and a hardness seven times greater than that of the substrate.

Development of Advanced Surface Enhancement Technology for Decreasing Wear and Corrosion of Equipment Used for Mineral Processing

“…Coating materials are fused by the PAL, yielding metallurgical bonding between coating and substrate. It was demonstrated that the method could fuse and metallurgically bond coatings and steel substrates without convective mixing, providing a new means for the rapid thermal processing of surface coatings (Engleman et al, 2002). It has been applied to the treatment of metals Muralidharan et al, 2004).…”

“…It has been applied to the treatment of metals Muralidharan et al, 2004). HDI surface treatment process has been successfully applied in the wear parts used for bulldozers manufactured by the Caterpillar Inc. More than 5-fold of wear enhancement has been achieved (Blue, 2002). Advantages of using a plasma radiant source to fuse coatings include: …”

“…WC has high hardness, good strength and is stable with Ni-P base materials. It has been shown the successful application of WC coating with Ni-P base greatly increased coating wear resistance of HID-treated samples (Engleman et al, 2002). Iron-based amorphous materials, for example (Fe-15Cr-14Mo-2Y-15C-6B, wt%), have been reported to have high strength and good wear resistance as well (Pang, 2002).…”

A numerical study on parameter control for remelted coating processes

“…To improve the properties of sprayed coatings, an additional high intensity energy source has been commonly used, including lasers [2][3][4][5] and infrared radiation [6,7]. Lasers are promising technological tools due to their speedy application and simplicity of process control.…”