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Improvement in thermal stability and tribological properties of nanostructured WC-Co coatings deposited by HVOF spraying View project
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In carbide cermet coatings, such as WC–Co–Cr, the surface roughness of the sprayed workpiece is much more than the acceptable values
for various industrial demands. Thus, the surface of the carbide cermet coatings is to be ground appropriately to obtain suitable surface
finish. However, the grinding may change the properties of coating. In this study, effects of the grinding process on the porosity content,
residual stress, microhardness, and adhesion and cohesion strength of the high-velocity oxy-fuel WC–10Co–4Cr coatings are investigated.
For this purpose, the grinding experiments have been performed on a surface grinder using a diamond wheel (resin bond) under different
grinding parameters, such as table feed rate, cutting speed, and depth of cut. The investigations of residual stress state and adhesion proper-
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ties were carried out using the X-ray diffraction and interfacial indentation test methods, respectively. The results indicated that the coat-
ing’s porosity content increased after grinding due to the mechanical loading of coating by diamond grits of the grinding wheel. On the other
hand, adhesion and cohesion strength and microhardness of the coating were improved after grinding. This can be interpreted by the
residual stress state of the coating samples.
Keywords Adhesion; Coating; Cohesion; Grinding; Hvof; Microhardness; Porosity; Residual stress; WC–10Co–4Cr.
1139
1140 H. MASOUMI ET AL.
coating adhesion to the substrate. The WC–10Co–4Cr technique [16]. Since WC–10Co–4Cr is a multiphase
powders (GTV number 80.76.1 produced by GTV Com- cermet coating and tungsten carbide symbolizes the main
pany, Germany) were used in this work. The shape of phase of this coating, the residual stress determination
this powder was spherical and the grain size was 45 comprised precise measurement of the peak shift of the
to þ20 mm. In this work, a Metjet-III system (Metalliza- tungsten carbide Bragg monitored at 2h ¼ 84.14 , since
tion, UK) was employed to spray WC–10Co–4Cr no peak interference was observed. Thus, the residual
powders onto substrates using HVOF process. The coat- stress of the coating specimens was calculated by the WC
ing thickness was approximately 400 mm. The spraying reflection in a 2h measuring range of 82–86 . The anode
conditions are illustrated in Table 1. settings were current of 40 mA and tube voltage of 40 kV.
In the as-sprayed sample, the XRD measurement was
Grinding Procedure carried out in the longitudinal and transverse directions
Grinding experiments were carried out under down with stress components rxx and ryy, corresponding to
grinding configuration on an IMTI (Industrial Machine azimuth angles / ¼ 0 and / ¼ 90 , respectively. Also,
Tool, Inc., USA) surface grinding machine. A diamond in the as-ground coating samples, the stress values paral-
wheel (resin bond) with a diamond concentration number lel to (rxx or r11: / ¼ 0 ) and perpendicular to (ryy or r?:
of 75 (3.3 carats=cm3) and an average grain size of 76 mm / ¼ 90 ) the grinding direction were considered, as
was employed. Diameter, width, and diamond thickness shown in Fig. 1(a). For each azimuth angle /, peaks
of the wheel were 350, 15, and 5 mm, respectively. were recorded at 11 tilt angles w between 40 and
Water-based emulsion was employed as the grinding fluid. þ40 (0, 16.71, 23.99, 29.86, 35.10, 40).
Grinding conditions are as follows: depth of cut ap ¼ 4, 10, It has been proved that the measured strain e/w along
16, and 22 mm, feed rate vw ¼ 142, 273, 413, and 550 mm=s, the / and w direction can be related to the stresses using
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and cutting speed vs ¼ 20, 25, 30, and 35 m=s. the following equation [16]:
FIGURE 1.—Schematic view of the: (a) sample geometry and measurement directions of residual stresses, (b) IIT method [17], (c) indentation impressions of
Vickers indenter at the coating cross-section and at the coating–substrate interface [18], and (d) IIT results [17].
Microhardness. The Vickers hardness test is the d=2, are measured at the interface by optical microscopy
standard microhardness test employed for thermal spray [Fig. 1(c)]. They are plotted versus the applied loads in
coatings [1]. The microhardness measurements of the bilogarithmic scale [Fig. 1(d)]. Finally, the critical point
WC–10Co–4Cr coatings were obtained by a Micromet coordinates (Pc, ac) are determined as the intersection
(Buehler, Japan) microhardness tester using a Vickers point between extrapolated lines lnP – lnd and lnP – lna.
diamond indenter. The microhardness measurements Using the critical parameters for cracking, Pc and ac,
were carried out on the polished cross-section of the under which no crack generates in the coating–substrate
coatings so that the measurements are not influenced interface, apparent interfacial fracture toughness, Kca,
by the steel substrate. The dwell time of the load and can be expressed as [17]
the applied load were 20 s and 300 g, respectively. For
each specimen, the measurement of microhardness was 1=2
carried out five times and the average values were Pc
E
Kca ¼ 0:015 3=2 ð5Þ
computed. ac H i
1=2
Adhesion and cohesion strength. There are many where ðE=H Þi is the square root of the ratio of the
approaches to determine cohesion and adhesion strength modulus of elasticity and the hardness at the coating–
of thermal spray coatings. Among them, tensile substrate interface. It is defined as [17]
adhesion test (TAT) standardized in ASTM C633 is
1=2
commonly employed. However, the TAT technique is E ðE=H Þ1=2
c ðE=H Þ1=2
s
not appropriate for as-ground coating samples. Grind- ¼ 1=2
þ ð6Þ
ing of samples prior to applying the adhesive for TAT H i 1 þ ðHc =Hs Þ 1 þ ðHs =Hc Þ1=2
minimizes the mechanical interlocking and it may tend
to activate the surface for chemical reaction with the where H is the hardness, E is the modulus of elasticity,
epoxy [1]. For this reason, in this study the interfacial and subscripts c and s denote coating and substrate,
indentation test (IIT) has been employed to evaluate respectively.
the adhesion strength of as-sprayed and as-ground The fracture toughness of coating, Kc, which may be a
samples. symbol of the coating cohesive properties, is calculated
The principle of the IIT method is the loading pyrami- using Vickers indentation approach. The following
dal Vickers diamond indenter on the cross-section of the equation is employed to obtain Kc [18]:
coating–substrate interface at varying applied loads to
develop and propagate a crack along the interface, as
P E 1=2
illustrated in Fig. 1(b). For each test of indentation, Kc ¼ 0:016 3=2 ð7Þ
the crack length, a, and the half diagonal of the indenter, c H
1142 H. MASOUMI ET AL.
where P, c, E, and H are the applied load, the crack photograph are illustrated in Fig. 2(c) and 2(d), respect-
length [Fig. 1(c)], the Young’s modulus of coating, and ively. Experimental results demonstrated that after
the coating hardness, respectively. grinding there was a slight increase in the WC–10Co–
In this study, cohesive and adhesive properties of the 4Cr coating porosity, as shown in Fig. 2(e). Almost in
HVOF WC–10Co–4Cr coatings were examined by all the studied ranges of the grinding parameters, the
Vickers indentation method by means of a 2RC-S Dia porosity content of coating increased after grinding.
Tester (Wolpert) hardness testing machine. This is owing to a little amount of microcracks gener-
ated by the grinding process [indicated by arrows in
Fig. 2(c)], that is, due to the mechanical loading of
RESULTS AND DISCUSSION coating by diamond grits of the grinding wheel. The
Porosity microcracks themselves and the pores caused by WC
Figure 2(a) and 2(b) illustrates a typical SEM image of particles dislodgment during polishing due to the exist-
the transverse section of WC–10Co–4Cr coating sample ence of microcracks are the possible reasons for an
in as-coated condition and the corresponding image increase in porosity content after grinding.
analysis photograph. As can be seen in this figure, the Representative results for the porosity content of
porosity content is very low. The average percent of as-ground coating samples as a function of depth of
porosity content for coating samples before grinding cut, table feed rate, and wheel speed have been illu-
was 0.83. This was expected due to the high particle strated in Fig. 3(a)–3(c), respectively. As can be seen,
impact velocity in HVOF process, since it compresses when ap and vw were increased or vs was decreased, there
most air pockets out of the coating microstructure. was a little increase in porosity content. The reason for
A typical SEM photograph of the as-ground these variations is the rising applied mechanical load
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coating sample and the corresponding image analysis on coating by increasing ap and vw or by decreasing vs.
FIGURE 2.—(a) SEM image of the transverse section of the as-coated WC–10Co–4Cr coating sample and (b) the corresponding image analysis photograph
(porosity ¼ 0.80%), (c) SEM image of the transverse section of the as-ground WC–10Co–4Cr coating sample (ap ¼ 4 mm, vw ¼ 142 mm=s, and vs ¼ 30 m=s)
and (d) the corresponding image analysis photograph (porosity ¼ 0.96%), (e) comparison of coating porosity content before and after grinding.
EFFECT OF GRINDING ON THE RESIDUAL STRESS AND ADHESION STRENGTH 1143
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FIGURE 3.—Porosity content of WC–10Co–4Cr coating vs. (a) depth of cut (vw ¼ 550 mm=s and vs ¼ 30 m=s), (b) feed rate (ap ¼ 22 mm and vs ¼ 20 m=s),
(c) cutting speed (ap ¼ 4 mm and vw ¼ 142 mm=s), and (d) maximum undeformed chip thickness.
It can be related in turn to the maximum undeformed where f, dg, and v are the proportion of abrasive grains
chip thickness, hm, parameter. The value of hm is that actively involved in cutting action, the average
considered as the abrasive grit penetration into the diameter of abrasive grits, and the volume proportion
workpiece and in that sense is the grain depth of cut, of abrasive particles in the grinding wheel, respectively.
and can be approximated as [20] In this work, f ¼ 0.5 by assuming that 1=2 of the dia-
mond grits on the surface of the wheel are actively
" 1=2 #1=2 involved in the grinding process. The concentration
3 vw ap
hm ¼ ð8Þ number of the wheel used in this experiment was 75 that
Ctan h vs ds is equivalent to 3.3 carat=cm3 by weight or 18.75% by
volume of diamond abrasive on wheel, thus the volume
Where h, C, and ds are the semi-included angle of fraction is 0.1875. Also, the average diameter of abrasive
undeformed chip cross-section, the active abrasive grit grits is dg ¼ 76 mm. Substituting the values of f, v, and dg
density, and the grinding wheel diameter, respectively. in Eq. (9), gives C ¼ 43.65 mm2.
With the increase of ap and vw, and=or with the decrease
of vs, the value of hm is increased (Eq. (8)). On the other Residual Stress
hand, the grinding force increases according to the rise The measurement of coating residual stress was
in the grit depth of cut [13]. At the same time, the performed using XRD method and sin2w technique.
applied mechanical load on coating is increased, and Figure 4(a) shows a typical plot of dw vs. sin2w for as-
thus leads to an increase in microcracks and therefore sprayed coating in the transverse direction. The dw vs.
to an increase in porosity content [Fig. 3(d)]. sin2w of the coating shows a negative slope that indicates
Equation (8) was employed to calculate the value of a compressive residual stress. According to the XRD
hm parameter in Fig. 3(d). For this purpose, ds ¼ 350 mm measurement results, the residual stresses of as-sprayed
mm and h was assumed to be 60 . Also, the value of C WC–10Co–4Cr coating in both longitudinal and trans-
has been calculated by the geometric equation [21]: verse directions were compressive and their values were
rxx ¼ 125.8 MPa and ryy ¼ 133.4 MPa, respectively.
4f The slight difference between the values of residual stress
C¼ ð9Þ in longitudinal and transverse directions reveals that there
dg ð4p=3vÞ2=3
2
is no residual stress anisotropy in as-coated sample.
1144 H. MASOUMI ET AL.
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FIGURE 4.—(a) The plot of dw vs. sin2w for as-coated WC–10Co–4Cr sample in the transverse direction (/ ¼90 ), (b) comparison of residual stress state
of WC–10Co–4Cr coating before and after grinding, and (c) SEM surface observation of the HVOF-sprayed coating ground by the resinoid-bonded
diamond wheel under ap ¼ 4 mm, vw ¼ 550 mm=s, and vs ¼ 30 m=s.
In this work, the residual stress of as-coated WC– 5.5 106K1, respectively. Thus, the mismatch stress
10Co–4Cr specimen had a compressive direction, which is compressive, since as the temperature decreases, the
agrees with the residual stress distributions reported for coating contracts by a smaller amount than the
as-sprayed WC–Co based coatings by many researchers substrate.
[7, 9]. Basically, residual stress generation in HVOF Considering the results mentioned above, the nature
coating arise from quenching, peening, and mismatch of the overall residual stresses in the as-coated WC–
of thermal expansion coefficient between substrate and 10Co–4Cr samples are determined by the combined
coating [22]. In this work, for WC–10Co–4Cr powder, effect of the tensile quenching stress, the compressive
the WC particles were not softened by the HVOF tem- peening stress, and the compressive mismatch stress.
perature. The impingement of these hard and solid par- The final residual stresses of WC–10Co–4Cr coating
ticles to steel substrate or to successive coating layers at had a compressive nature indicating that the mismatch
high velocity of HVOF process caused plastic defor- and peening components have a decisive role in the final
mation on the pre-deposited layer and therefore induced direction of the residual stress. The coefficient of thermal
the residual stress in compressive direction. In fact, the expansion for substrate is more than twice of that for
mass kinetic energy of WC particles is converted into HVOF WC–10Co–4Cr coating; it is a dominant factor
compressive stress. Conversely, the quenching stress is in the resultant compressive nature of the overall
always tensile. Quenching stress originates from the residual stress.
restrained contraction of individual spray particles when The XRD method was also employed to determine the
they cool down rapidly to the substrate temperature. coating residual stress after grinding under different con-
However, the quenching stress is in many conditions ditions. The average value of residual stresses obtained
relatively low (less than 100 MPa) [14]. On the other from all ground coating samples was compared with
hand, the direction of mismatch stress is dependent on that from as-sprayed sample in both longitudinal and
the relationship between the substrate and coating transverse directions in Fig. 4(b). As illustrated, the
thermal expansion coefficients. Mismatch stress can be residual stresses of as-ground coatings were compressive
either tensile or compressive [22]. In this work, similar to those in the as-sprayed coating. However, the
the thermal expansion coefficient of steel substrate compressive residual stress of the as-ground samples was
and WC–10Co–4Cr coating were 12 106K1 and higher than that of the as-coated sample.
EFFECT OF GRINDING ON THE RESIDUAL STRESS AND ADHESION STRENGTH 1145
Basically, residual stresses in ground samples can of the Hertzian loads and shear forces from the grinding
originate due to combination of three main mechanisms: wheel during the diamond grits-coating surface interac-
thermal-plastic deformation, mechanical-plastic defor- tion. As shown in the SEM photograph of the ground
mation, and phase transformation [23]. Grinding surface of the HVOF-coated WC–10Co–4Cr specimen
investigations proved that the most important para- in Fig. 4(c), the mechanical action of the diamond
meter in the residual stresses generation in tensile abrasive grits causes permanent plastic deformation in
direction during grinding is thermal expansion and con- the coating surface, avoiding the full recovery of
traction (thermal-plastic deformation) [24]. Since the sub-layer elastic deformation, and thus increasing the
appropriate coolant was employed during grinding in magnitude of the coating residual stresses in compress-
this work, the amount of heat induced into the coating ive direction.
was minimal. It was found that the lower temperature Figure 5(a)–5(c) shows the influence of grinding para-
of grinding process causes reduced or complete elimin- meters on the residual stress. As can be observed in this
ation of residual stresses in tensile direction [24]. Thus, figure, in all the grinding experiment conditions, the
the thermal-plastic deformation could not be considered residual stress values normal to the grinding direction
as an effective mechanism for the variations in the were higher than those in parallel direction. The reason
residual stress values after grinding. On the other hand, for such residual stress anisotropy in as-ground coating
phase transformation could be an important factor in samples lie in the fact that the volume of coating normal
generation of residual stress, usually in grinding of to the grinding direction was deformed more plastically
hardened steels [23]. Furthermore, it was reported that than that along the grinding direction by ductile flow
no phase transformations have been shown in the due to plowing [Fig. 4(c)].
HVOF WC–Co based coatings during grinding [7]. In The values of the compressive residual stresses
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fact, no such transformation will occur if suitable heat- increases with increasing ap and vw, and with decreasing
dissipation conditions are provided during grinding. vs, but there is a decrease in r? as ap increases from 16 to
Therefore, in this work, mechanical-plastic deformation 22 mm, and in r11 as vs decreases from 25 to 20 m=s, as
may be the main reason for an increase in the residual can be observed in Fig. 5. However, the increase trend
stresses values in compressive direction after grinding. is very obvious. The higher compressive residual stresses
It was found that the grinding-induced residual at higher depth of cut and feed rate values, and at lower
stresses due to mechanical-plastic deformation have a cutting speed values originate from larger grain depth of
compressive nature [23, 24]. The grinding-induced cut and thus larger grinding force with more extent of
residual stresses in compressive direction are because plastic deformations due to mechanical action of the
FIGURE 5.—Compressive residual stresses of WC–10Co–4Cr coating vs. (a) depth of cut (vw ¼ 550 mm=s and vs ¼ 30 m=s), (b) feed rate (ap ¼ 22 mm and
vs ¼ 20 m=s), and (c) cutting speed (ap ¼ 4 mm and vw ¼ 142 mm=s).
1146 H. MASOUMI ET AL.
diamond abrasive grains. In fact, compressive residual residual stress has been studied in the next sections using
stresses increase with increasing amounts of plastic the investigation of the adhesion and cohesion strength
deformation. and the microhardness of coating.
Machining-induced residual stress is a critical para-
meter for fatigue life of products [25]. According to the
results mentioned in this section, the residual stresses of Microhardness
as-coated HVOF WC–10Co–4Cr sample had a compress- The microhardness measurements of the HVOF WC–
ive nature and this stress had increased in compressive 10Co–4Cr coating samples were carried out on the
direction after grinding. Compressive stress improves polished cross-section. The average Vickers microhard-
the components strength, whereas tensile stress is almost ness of the as-sprayed coating was 1347.3 Kg=mm2. In
always deleterious [24]. The residual stress in compressive this research, the measured microhardness of as-sprayed
direction can improve resistance to stress corrosion coating was generally higher than that reported for
cracking and fatigue fracture of the coating [26]. The HVOF WC–Co based coatings by other researchers [7,
improvement of the performance of WC–10Co–4Cr coat- 9]. This is possible because of the different HVOF pro-
ing after grinding because of the increased compressive cess parameters and because of the existence of the Cr
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FIGURE 6.—(a) Comparison of microhardness values of WC–10Co–4Cr coating before and after grinding; microhardness values of as-ground WC–10Co–
4Cr coating vs. (b) depth of cut (vw ¼ 273 mm=s and vs ¼ 25 m=s), (c) feed rate (ap ¼ 22 mm and vs ¼ 30 m=s), (d) cutting speed (ap ¼ 10 mm and
vw ¼ 273 mm=s), and (e) maximum undeformed chip thickness.
EFFECT OF GRINDING ON THE RESIDUAL STRESS AND ADHESION STRENGTH 1147
in coating. In general, high microhardness values of variation, as illustrated in Fig. 5. As can be observed
HVOF WC–Co based coatings are because of the fact in Fig. 6(b) and 6(c), the coating’s microhardness
that these coatings show a high compact and dense increased with increasing ap and vw because of the
microstructure, since the particles of WC–Co are increased residual stress in compressive direction at the
imparted in the substrate with a relatively high velocity. higher values of ap and vw due to the larger maximum
Also, the hard WC phase (2400 HV [22]) in this cermet undeformed chip thickness values. Increasing hm values
coatings lead to high coating microhardness. resulted in increases of grit depth of cut, grinding force,
As previously mentioned, the magnitude of the coat- and thus plastic deformation, at the same time, the
ing porosity was increased after grinding. On the other coating’s microhardness is increased with increasing
hand, the increase of porosity leads to a decrease of compressive residual stress [Fig. 6(e)]. The effect of
coating hardness [22]. Thus, it is expected that the decreasing cutting speed is similar to that discussed for
microhardness of HVOF WC–10Co–4Cr coating after increasing ap and vw [Fig. 6(d)]. All these processing
grinding should be lower than that before grinding. effects are related to variations in grit depth of cut.
However, as illustrated in Fig. 6(a), experimental results
demonstrate that there is an obvious increase in the
microhardness values of WC–10Co–4Cr coating after Adhesion and Cohesion Strength
grinding. The reason for such unexpected behavior is The Vickers indentation tests at the coating–substrate
the increased compressive residual stress in coating after interface were employed to evaluate the adhesion
grinding. It can therefore be stated that the residual strength of WC–10Co–4Cr coating. The indentation
stress is more effective than the coating porosity content tests were carried out with loads varying from 1 to
in determining the microhardness of the WC–10Co–4Cr 31.250 kg. Figure 7 illustrates the typical optical micro-
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FIGURE 7.—Example of crack observations for as-sprayed coating at the different applied loads: (a) 5 kg, (b) 10 kg, (c) 15.625 kg, and (d) 20 kg; and
(e) representation of lnP–lna relation.
1148 H. MASOUMI ET AL.
TABLE 2.— Mechanical characteristics of coating, substrate, and coating– 10Co–4Cr coating. The fracture toughness, which may
substrate interface. be a symbol of the cohesion properties of the WC–
E 1=2 10Co–4Cr coating, was calculated using the Eq. (7).
Young’s modulus Vickers microhardness H The average value of Kc ¼ 2.825 MPa m1=2 was obtained
WC–10Co–4Cr Ec ¼ 316 GPa Hc ¼ 13.217 GPa E 1=2 for the coating in as-sprayed condition.
¼ 4.890
coating
H c A similar procedure was employed to determine the
Low carbon steel Es ¼ 211 GPa Hs ¼ 1.629 GPa E 1=2 values of Kca and Kc for WC–10Co–4Cr coating samples
H s ¼ 11.381
substrate after grinding under different process parameters. Con-
E 1=2
Coating–
H i ¼ 9.694 trary to as-sprayed samples, for most of the as-ground
substrate coating specimens, no crack was seen when the Vickers
interface test was performed using a 5 kg load. Figure 8 presents
the lnP–lna plots of the as-ground samples under differ-
ent grinding conditions. The corresponding values of Pc
ac ¼ 74.72 mm) was determined as the point that and ac are shown in this figure. The average values of Kca
underneath no interface cracking is seen. Table 2 collects and Kc obtained from all ground coating samples were
the calculated values and the experimental results as well compared with that from as-sprayed sample in Fig. 9(a)
as the hardness (Section 3.3) data and the elastic and 9(b). As can be observed, both Kca and Kc values of
modulus (from Nanoindentation test) necessary for the the HVOF WC–10Co–4Cr coating increased after
computation of the Kca. The apparent interfacial frac- grinding. By comparing Fig. 9(a) and 9(b) through
ture toughness was calculated by Eq. (5), and the aver- Fig. 6(a), it is seen that both fracture toughness and
age value of Kca ¼ 10.946 MPa m1=2 was obtained for microhardness have similar trends versus grinding pro-
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as-sprayed coating. cess. The reason for this behavior is the increased com-
Also, the Vickers indentation tests within the coating pressive residual stress in coating after grinding.
were used to evaluate the cohesion strength of WC– Considering that there was an increase in the porosity
FIGURE 8.—Relation between indentation loads (P) and corresponding crack lengths (a) for as-ground coating samples, under vw ¼ 550 mm=s and
vs ¼ 30 m=s, at (a) ap ¼ 4 mm, (b) ap ¼ 10 mm, (c) ap ¼ 16 mm, and (d) ap ¼ 22 mm; under ap ¼ 22 mm and vs ¼ 20 m=s, at (e) vw ¼ 142 mm=s, (f) vw ¼ 273 mm=s,
(g) vw ¼ 413 mm=s, and (h) vw ¼ 550 mm=s; under ap ¼ 4 mm and vw ¼ 142 mm=s, at (i) vs ¼ 20 m=s, (j) vs ¼ 25 m=s, (k) vs ¼ 30 m=s, and (l) vs ¼ 35 m=s.
EFFECT OF GRINDING ON THE RESIDUAL STRESS AND ADHESION STRENGTH 1149
FIGURE 9.—(a) Comparison of Kca values of coating before and after grinding, (b) Comparison of Kc values of coating before and after grinding; Kca values
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of WC–10Co–4Cr coating vs. (c) hm, (d) ap (vw ¼ 550 mm=s and vs ¼ 30 m=s), (e) vw (ap ¼ 22 mm and vs ¼ 20 m=s), and (f) vs (ap ¼ 4 mm and vw ¼ 142 mm=s).
content of WC–10Co–4Cr coating after grinding, it can enhances the interfacial adhesion, while tensile stress
therefore be inferred that the residual stress is more promotes the interfacial debonding.
effective than the coating porosity content in determin- The improvement of the adhesion and cohesion
ing the adhesion and cohesion strength of the WC– strength of coating samples after grinding [Fig. 9(a)
10Co–4Cr coating. and 9(b)] due to the increased residual stress in com-
Figure 9(d)–9(f) summarizes the average values of pressive direction can also be explained by the corre-
interfacial fracture toughness as a function of ap, vw, lation between inter-atomic spacing and residual stress
and vs, respectively. As can be seen, the magnitude of conditions. It has been proved that atoms locate at a
the interfacial fracture toughness increased with ap and balanced inter-atomic distance, r0. Theoretically, the
vw and decreased as vs was elevated. Similar behavior atomic bonds start breaking (or the cracks start grow-
was observed in the case of coating fracture toughness. ing) when the inter-atomic distance reaches a value over
Increasing ap and vw or decreasing vs, increases maxi- than rmax under a tensile force larger than the maximum
mum undeformed chip thickness, increases mechanical atomic bonding force, Fmax. When the final residual
loading of abrasive grits during grinding, increases com- stresses of coating have a compressive nature, the
pressive residual stresses of coating, and thus increases inter-atomic spacing is reduced, and thus the greater
fracture toughness [Fig. 9(c)]. applied forces are required to break atomic bonds [29].
As previously mentioned, the residual stresses of the Therefore, the adhesion and cohesion strength of the
HVOF WC–10Co–4Cr coating increased in compressive HVOF WC–10Co–4Cr coatings containing higher
direction after grinding. It has been proved that the values of compressive residual stresses were observed
compressive residual stress in coating prevents crack higher than those with lower values of compressive
initiation and propagation [27]. In fact, the coating stresses [Fig. 9(d)–9(f)].
residual stresses in compressive direction would delay
the effect of applied shear stresses and blunt the tips of
CONCLUSIONS
cracks, therefore preventing crack initiation and propa-
gation. Thus, the higher mechanical properties are In this research, the adhesion and cohesion strength,
observed for the coating with the higher values of com- porosity, and microhardness of the WC–10Co–4Cr coat-
pressive stress [29]. ings under the effect of residual stresses were studied.
Previous investigations [30] have shown that the com- From the experimental results, the most important
pressive residual stress can deform the coated sample conclusions can be summarized as follows:
and result in a convex curvature. On the other hand,
tensile residual stress can cause a concave curvature in . There was a little increase in the porosity content
coating. Thus, for the coating samples containing after grinding because of the induced microcracks
compressive and tensile residual stresses, the resultant by the grinding process due to the mechanical
bending moments at the coating–substrate interface loading of coating by diamond grits of the wheel.
are toward the substrate and toward the coating, . The residual stresses of as-sprayed WC–10Co–4Cr
respectively. Therefore, the compressive residual stress coating in both parallel and normal directions
1150 H. MASOUMI ET AL.
were compressive, and there was no residual stress 7. Murthy, J.K.N.; Rao, D.S.; Venkataraman, B. Effect of
anisotropy in as-sprayed coating. The mismatch grinding on the erosion behaviour of a WC-Co-Cr coating
and peening stress components have a decisive deposited by HVOF and detonation gun spray processes.
role in the final compressive direction of the Wear 2001, 249 (7), 592–600.
residual stress. 8. Thermal Spraying: Practice, Theory, and Application.
. The residual stresses of as-ground coating samples American Welding Society, 1985.
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