Investigating the Ability of Coating the SiC by APS and HVOF Processes through the Nickel-Phosphorus Cladding on the Primary Powder

مهندسی متالورژی و مواد

Article 8, Volume 34, Issue 4 - Serial Number 32, December 2023, Pages 17-30   

Document Type: Original Article

DOI: 10.22067/jmme.2023.81846.1107

Authors

Pejman Zamani Moghadam^{* 1}; Zia Valefi²; Masoud Mirjani²

¹Faculty of Materials and Manufacturing Technologies, Malek Ashtar University of Technology, Iran: Tehran,

²Faculty of Materials and Manufacturing Technologies, Malek Ashtar University of Technology, Iran

Abstract

In this research, silicon carbide (SiC) powder with a particle size of 30 to 45 micrometers and an irregular morphology was used for coating in an electroless nickel bath. The effect of particle surface roughening parameters in an acidic solution and electroless process time on uniformity and thickness of Ni-P coating on the SiC particles was investigated. SiC(Ni)-70vol.%Co blended powder was coated on simple carbon steel substrates by high-velocity oxy-fuel (HVOF) and atmospheric plasma spraying (APS) processes. The composite powder was obtained from the mechanical blending of cobalt powder with coated silicon carbide SiC(Ni) powder. The microstructure and morphology of powder particles and corresponding coatings were investigated by scanning electron microscopy (SEM). The results showed that the surface preparation of SiC powder by roughening the particles with HF/NaF solution and electroless time of 5 minutes led to the formation of a continuous and uniform Ni-P coating with a thickness of 1-3 micrometers on the SiC particles. Electroless nickel coating during thermal spraying by HVOF protected SiC particles against decomposition and oxidation and as a carrier led to the placement and distribution of SiC in SiC(Ni)-Co composite coating. In the APS process, due to the very high temperature of the plasma jet and thermal decomposition, SiC particles was insignificantly contributed to the coating microstructure. The micro-hardness of two mentioned coatings was measured as 570±40 and 460±30 HV0.3, respectively, and this difference was due to the effect of the significant distribution of SiC in the HVOF coating.

Keywords

Silicon carbide; Ni-P; Thermal spray; HVOF; APS

References

[1]   O. Dervis, “Structural characteristics and wear, oxidation, hot corrosion behaviors of HVOF sprayed Cr₃C₂-NiCr hardmetal coatings,” Surface and Coatings Technology, Vol. 457, pp. 129319, (2023).

[2]    P. Zamani, R. Ghasemi, S. Torabi, B. Mirjani, M. Memari, M. Alizadeh, H. Khaledi, “Characterization and High-Temperature Fretting Wear Resistance of HVOF-Sprayed Cr₃C₂-NiCr, CoCrWC and CoCrWNiC Hardfacing Coatings”, Journal of Thermal Spray Technology, Vol. 31, pp. 2157-2171, (2022).

[3]   V. Matikainen, G. Bolelli, H. Koivuluoto, P. Sassatelli, “Sliding wear behaviour of HVOF and HVAF sprayed Cr₃C₂-based coatings,” Wear, Vol. 388, pp. 57-71, (2017).

[4]   E. Jonda, M. Szala, M. Sroka, L. Łatka, M. Walczak, “Investigations of cavitation erosion and wear resistance of cermet coatings manufactured by HVOF spraying,” Applied Surface Science, Vol. 608, pp. 155071, (2023).

[5]   F. Mubarok, N. Espallargas, “Thermally sprayed SiC coatings for offshore wind turbine bearing applications,” Journal of thermal spray technology, Vol. 22, pp. 1303-1309, (2013).

[6]    F. Mubarok, N. Espallargas, “Suspension plasma spraying of sub-micron silicon carbide composite coatings,” Journal of Thermal Spray Technology, Vol. 24, pp. 817-825, (2015).

[7]   W. Li, Y. Yang, H. Li, X. Zhang, Y.W. Wang, W. Tian, “TEM characterization and reaction mechanism of composite coating fabricated by plasma spraying Nb–SiC composite powder,” Ceramics International, Vol. 19, pp. 15055-15064, (2023).

[8]   A. Abolkassem, A. Omayma, H. Ayman, “Effect of consolidation techniques on the properties of Al matrix composite reinforced with nano Ni-coated SiC,” Results in Physics, Vol. 9, pp. 1102-1111, (2018).

[9]   A. Elkady, A. Abolkassem, H. Elsayed, “Microwave absorbing efficiency of Al matrix composite reinforced with nano-Ni/SiC particles,” Results in Physics, Vol. 12, pp. 687-700, (2019).

[10] M. Rossetti, S. Mathiyalagan, S. Björklund, S. Sowers, S. Joshi, “Advanced diamond-reinforced metal matrix composite (DMMC) coatings via HVAF process: Effect of particle size and nozzle characteristics on tribological properties,” Ceramics International, Vol. 49, pp. 17838-17850, (2023).

[11] W. Riedel, Electroless Nickel Plating, ASM International, Ohio, (1991).

[12] S.K. Devarakonda, “Preparation and characterization of electroless Ni coated nano alumina powder under different sensitization activation conditions,” Metallurgical and Materials Engineering, Vol. 27, pp. 275-287, (2021).

[13] M.K. Pal, “Investigation of the electroless nickel plated sic particles in SAC305 solder matrix,” Powder Metallurgy and Metal Ceramics, Vol. 58, pp. 529-537, (2020).

[14] A. Heidarzadeh, T.M. Reza, “Optimizing the mass gain percentage during Ni electroless deposition on the SiC ceramic particles,” Materials Research Express, Vol. 5, pp. 096506, (2018).

[15] H.R. Shahverdi, M. Emami, R. Dinani, “Create a nickel-phosphorus coating on the surface of silicon carbide particles by electroless process,” 8^th Congress and 3^nd international Engineering Materials and Metallurgy, Iran, Nov. 18-19, (2014). (In Persian)

[16] A. Raza, F. Ahmad, T.M. Badri, M.R. Raza, K. Malik, “An Influence of Oxygen Flow Rate and Spray Distance on the Porosity of HVOF Coating and Its Effects on Corrosion—A Review,” Materials, Vol. 15, pp. 6329, (2022).

[17] M. Oksa, E. Turunen, T. Suhonen, T. Varis, S.P. Hannula, “Optimization and characterization of high velocity oxy-fuel sprayed coatings: techniques, materials, and applications,” Coatings, Vol. 1, pp. 17-52, (2011).

[18] P. Zamani, Z. Valefi, “Comparative investigation of microstructure and high-temperature oxidation resistance of high-velocity oxy-fuel sprayed CoNiCrAlY/nano-Al₂O₃ composite coatings using satellited powders,” International Journal of Minerals, Metallurgy and Materials, Vol. 18, No. 54, pp. 13-28, (2023).

[19] J. Xu, C. Zhang, G. Sun, J. Xiao, L. Zhang, G. Zhang, “Role of SiC nanoparticles on tribological properties of atmospheric plasma sprayed 5 wt% SiC–Ni60 coatings,” Tribology International, Vol. 146, pp. 106220, (2020).

[20] J.R. Davis, Surface engineering for corrosion and wear resistance, ASM international, (2001).

[21] K. Daviau, L. Kanani, “Decomposition of silicon carbide at high pressures and temperatures,” Physical Review B, Vol. 96, pp. 174102, (2017).

[22] A. Hähnel, E. Pippel, J. Woltersdorf, “Nanoprocesses of the Formation of Reaction Layers in Si‐C‐O Systems. Crystal Research and Technology,” Journal of Experimental and Industrial Crystallography, Vol. 35, pp. 663-674, (2000).

[23] E.A. Gulbransen, A.J. Sven, “The high-temperature oxidation, reduction, and volatilization reactions of silicon and silicon carbide,” Oxidation of metals, Vol. 4, pp. 181-201, (1972).

[24] H.K. Kang, B.K., Suk, “Thermal decomposition of silicon carbide in a plasma-sprayed Cu/SiC composite deposit,” Materials Science and Engineering: A, Vol. 428, pp. 336-345, (2006).

[25] S. Chelladurai, S. Jerold, “A review on mechanical properties and wear behavior of aluminum based metal matrix composites,” Materials Today: Proceedings, Vol. 37, pp. 908-916, (2021).

[26] R.K. Sharma, R.K. Das, S.R. Kumar, “Microstructure, mechanical and tribological properties of high velocity oxy fuel thermal spray coating: A review,” Materialwissenschaft und Werkstofftechnik, Vol. 54, pp. 90-97, (2023).

[27] S.W. Rukhande, W.S. Rathod, D. Bhosale, “High-temperature tribological investigation of APS and HVOF sprayed NiCrBSiFe coatings on SS 316L. Tribology-Materials,” Surfaces & Interfaces, Vol. 16, pp. 98-109, (2022).