Strategies for the Development of Wear-Resistant Coatings: A Review

Esta revisão apresenta possíveis estratégias para aumentar a resistência ao desgaste de revestimentos duros, baseado no projeto conjunto de matriz metálica e segunda fase dura. Como a resistência ao desgaste não é uma propriedade intrínseca do material, os resultados de vários ensaios de desgaste são discutidos à luz da interação entre propriedades mecânicas e severidade de desgaste, o que é dependente da microestrutura. Estas estratégias são baseadas no aumento de dureza, considerando o tipo e tamanho da segunda fase dura; a tenacidade à fratura e o nível de diluição do revestimento. As diretrizes fornecidas para o melhor projeto de ligas de revestimentos duros para condições usuais de abrasão dependem da fração volumétrica de segunda fase dura.

Palavras-chave:
Desgaste abrasivo; Revestimento duro; Carbonetos

Autoria

Giuseppe Pintaude

Universidade Tecnológica Federal do Paraná – UTFPR, Curitiba, PR, Brasil.Universidade Tecnológica Federal do ParanáBrasilCuritiba, PR, BrasilUniversidade Tecnológica Federal do Paraná – UTFPR, Curitiba, PR, Brasil.

https://orcid.org/0000-0001-8215-4481

E-mail: pintaude@utfpr.edu.br (GP)

SCIMAGO INSTITUTIONS RANKINGS

Figuras | Fórmulas

Figuras (10)
Fórmulas (2)

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Figure 1
The effect of carbide size on wear behavior of Co-base alloys during the DSRW test. Adapted from [¹⁶16 Desai VM, Rao CM, Kosel TH, Fiore NF. Effect of carbide size on the abrasion of cobalt-base powder metallurgy alloys. Wear. 1984;94(1):89-101. http://dx.doi.org/10.1016/0043-1648(84)90168-6.
http://dx.doi.org/10.1016/0043-1648(84)9... ].

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Figure 2
The blocking action promoted by a chromium carbide on a manual scratch did with a glass fragment [¹⁷17 Pintaude G, Bernardes FG, Santos MM, Sinatora A, Albertin E. Mild and severe wear of steels and cast irons in sliding abrasion. Wear. 2009;267(1-4):19-25. http://dx.doi.org/10.1016/j.wear.2008.12.099.
http://dx.doi.org/10.1016/j.wear.2008.12... ].

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Figure 3
Volume loss caused by silica as a function of binder mean free path [²²22 Larsen-Basse J, Koyanagi ET. Abrasion of WC-Co alloys by quartz. Journal of Lubrication Technology. 1979;101(2):208-211. http://dx.doi.org/10.1115/1.3453325.
http://dx.doi.org/10.1115/1.3453325... ].

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Figure 4
A two-step mechanism involved removing the second hard phase during abrasion [¹⁷17 Pintaude G, Bernardes FG, Santos MM, Sinatora A, Albertin E. Mild and severe wear of steels and cast irons in sliding abrasion. Wear. 2009;267(1-4):19-25. http://dx.doi.org/10.1016/j.wear.2008.12.099.
http://dx.doi.org/10.1016/j.wear.2008.12... ,²¹21 Wang Q, Zhang Y, Ding X, Wang S, Ramachandran CS. Effect of WC grain size and abrasive type on the wear performance of HVOF-sprayed WC-20Cr3C2-7Ni coatings. Coatings. 2020;10(7):660. http://dx.doi.org/10.3390/coatings10070660.
http://dx.doi.org/10.3390/coatings100706... -²²22 Larsen-Basse J, Koyanagi ET. Abrasion of WC-Co alloys by quartz. Journal of Lubrication Technology. 1979;101(2):208-211. http://dx.doi.org/10.1115/1.3453325.
http://dx.doi.org/10.1115/1.3453325... ].

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Figure 5
Variation of abrasion resistance as a function of fracture toughness for materials with a relatively low volume fraction of the second hard phase. Adapted from [²⁵25 Zum Gahr KH, Doane DV. Optimizing fracture toughness and abrasion resistance in white cast irons. Metallurgical Transactions. A, Physical Metallurgy and Materials Science. 1980;11(4):613-620. http://dx.doi.org/10.1007/BF02670698.
http://dx.doi.org/10.1007/BF02670698... ].

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Figure 6
Variation of fracture toughness of carbides in high-chromium cast iron as a function of matrix hardness, using Vickers hardness test. Adapted from [²⁷27 Franco SD, Sinatora A. Determinação da tenacidade à fratura de carbonetos M7C3 usando o método da indentação. In: Anais do XI Congresso Brasileiro de Engenharia e Ciência dos Materiais; 1994; Águas de São Pedro. São Paulo: IPEN; 1994. p. 247-50.].

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Figure 7
Effect of difference in the metallic matrix’s hardness and carbides of high-chromium cast iron on wear resistance determined in DRSW testing. Adapted from [²⁸28 Kim CK, Lee S, Jung JY. Effects of heat treatment on wear resistance and fracture toughness of duo-cast materials composed of high-chromium white cast iron and low-chromium steel. Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science. 2006;37(3):633-643. http://dx.doi.org/10.1007/s11661-006-0035-9.
http://dx.doi.org/10.1007/s11661-006-003... ].

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Figure 8
Microcracking of MC carbide observed in a softer multicomponent cast iron abraded by 0.2 mm alumina paper [¹⁷17 Pintaude G, Bernardes FG, Santos MM, Sinatora A, Albertin E. Mild and severe wear of steels and cast irons in sliding abrasion. Wear. 2009;267(1-4):19-25. http://dx.doi.org/10.1016/j.wear.2008.12.099.
http://dx.doi.org/10.1016/j.wear.2008.12... ].

Thumbnail

Figure 9
Variation of abrasion resistance with the fracture toughness (determined by indentation) of WC-Co alloys [³³33 Roebuck B, Gant AJ, Gee MG. Abrasion and toughness property maps for WC/Co hardmetals. Powder Metallurgy. 2007;50(2):111-114. http://dx.doi.org/10.1179/174329007X211526.
http://dx.doi.org/10.1179/174329007X2115... ].

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Figure 10
Resulted microstructure from PTA deposit of 45% wt. of chromium carbides onto NiAl alloy, processed with 100 A [³⁶36 Yano DH, Brunetti C, Pintaude G, D’Oliveira ASCM, Canale L, Dean SW. Modification of NiAl intermetallic coatings processed by PTA with chromium carbides. Journal of ASTM International. 2011;8(4):1-11. http://dx.doi.org/10.1520/JAI103439.
http://dx.doi.org/10.1520/JAI103439... ].

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(1)

Thumbnail

(2)

Figure 1 The effect of carbide size on wear behavior of Co-base alloys during the DSRW test. Adapted from [¹⁶16 Desai VM, Rao CM, Kosel TH, Fiore NF. Effect of carbide size on the abrasion of cobalt-base powder metallurgy alloys. Wear. 1984;94(1):89-101. http://dx.doi.org/10.1016/0043-1648(84)90168-6.
http://dx.doi.org/10.1016/0043-1648(84)9... ].

Figure 2 The blocking action promoted by a chromium carbide on a manual scratch did with a glass fragment [¹⁷17 Pintaude G, Bernardes FG, Santos MM, Sinatora A, Albertin E. Mild and severe wear of steels and cast irons in sliding abrasion. Wear. 2009;267(1-4):19-25. http://dx.doi.org/10.1016/j.wear.2008.12.099.
http://dx.doi.org/10.1016/j.wear.2008.12... ].

Figure 3 Volume loss caused by silica as a function of binder mean free path [²²22 Larsen-Basse J, Koyanagi ET. Abrasion of WC-Co alloys by quartz. Journal of Lubrication Technology. 1979;101(2):208-211. http://dx.doi.org/10.1115/1.3453325.
http://dx.doi.org/10.1115/1.3453325... ].

Figure 4 A two-step mechanism involved removing the second hard phase during abrasion [¹⁷17 Pintaude G, Bernardes FG, Santos MM, Sinatora A, Albertin E. Mild and severe wear of steels and cast irons in sliding abrasion. Wear. 2009;267(1-4):19-25. http://dx.doi.org/10.1016/j.wear.2008.12.099.
http://dx.doi.org/10.1016/j.wear.2008.12... ,²¹21 Wang Q, Zhang Y, Ding X, Wang S, Ramachandran CS. Effect of WC grain size and abrasive type on the wear performance of HVOF-sprayed WC-20Cr3C2-7Ni coatings. Coatings. 2020;10(7):660. http://dx.doi.org/10.3390/coatings10070660.
http://dx.doi.org/10.3390/coatings100706... -²²22 Larsen-Basse J, Koyanagi ET. Abrasion of WC-Co alloys by quartz. Journal of Lubrication Technology. 1979;101(2):208-211. http://dx.doi.org/10.1115/1.3453325.
http://dx.doi.org/10.1115/1.3453325... ].

Figure 5 Variation of abrasion resistance as a function of fracture toughness for materials with a relatively low volume fraction of the second hard phase. Adapted from [²⁵25 Zum Gahr KH, Doane DV. Optimizing fracture toughness and abrasion resistance in white cast irons. Metallurgical Transactions. A, Physical Metallurgy and Materials Science. 1980;11(4):613-620. http://dx.doi.org/10.1007/BF02670698.
http://dx.doi.org/10.1007/BF02670698... ].

Figure 6 Variation of fracture toughness of carbides in high-chromium cast iron as a function of matrix hardness, using Vickers hardness test. Adapted from [²⁷27 Franco SD, Sinatora A. Determinação da tenacidade à fratura de carbonetos M7C3 usando o método da indentação. In: Anais do XI Congresso Brasileiro de Engenharia e Ciência dos Materiais; 1994; Águas de São Pedro. São Paulo: IPEN; 1994. p. 247-50.].

Figure 7 Effect of difference in the metallic matrix’s hardness and carbides of high-chromium cast iron on wear resistance determined in DRSW testing. Adapted from [²⁸28 Kim CK, Lee S, Jung JY. Effects of heat treatment on wear resistance and fracture toughness of duo-cast materials composed of high-chromium white cast iron and low-chromium steel. Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science. 2006;37(3):633-643. http://dx.doi.org/10.1007/s11661-006-0035-9.
http://dx.doi.org/10.1007/s11661-006-003... ].

Figure 8 Microcracking of MC carbide observed in a softer multicomponent cast iron abraded by 0.2 mm alumina paper [¹⁷17 Pintaude G, Bernardes FG, Santos MM, Sinatora A, Albertin E. Mild and severe wear of steels and cast irons in sliding abrasion. Wear. 2009;267(1-4):19-25. http://dx.doi.org/10.1016/j.wear.2008.12.099.
http://dx.doi.org/10.1016/j.wear.2008.12... ].

Figure 9 Variation of abrasion resistance with the fracture toughness (determined by indentation) of WC-Co alloys [³³33 Roebuck B, Gant AJ, Gee MG. Abrasion and toughness property maps for WC/Co hardmetals. Powder Metallurgy. 2007;50(2):111-114. http://dx.doi.org/10.1179/174329007X211526.
http://dx.doi.org/10.1179/174329007X2115... ].

Figure 10 Resulted microstructure from PTA deposit of 45% wt. of chromium carbides onto NiAl alloy, processed with 100 A [³⁶36 Yano DH, Brunetti C, Pintaude G, D’Oliveira ASCM, Canale L, Dean SW. Modification of NiAl intermetallic coatings processed by PTA with chromium carbides. Journal of ASTM International. 2011;8(4):1-11. http://dx.doi.org/10.1520/JAI103439.
http://dx.doi.org/10.1520/JAI103439... ].

(1)

\frac{d V}{d l} = \frac{t a n θ}{π} \frac{W}{H}

(2)

\frac{d V}{d l} = k \frac{d^{1 / 2}}{K_{I C}^{3 / 4}} \frac{p^{5 / 4}}{H^{1 / 2}}

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[1] E-mail: pintaude@utfpr.edu.br (GP)