Submit to Materials Review for Materials Propose a Special Issue

Journal Browser

Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials

Print Special Issue Flyer
Special Issue Editors
Special Issue Information
Keywords
Published Papers

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 December 2023) | Viewed by 21259

Share This Special Issue

Special Issue Editors

Dr. Artur Czupryński

E-Mail Website
Guest Editor

Department of Welding Engineering, Faculty of Mechanical Engineering, Silesian University of Technology, Konarskiego 18A Str., 44-100 Gliwice, Poland
Interests: welding; hardfacing; thermal spraying; explosive cladding process; brazing welding; surface engineering; abrasive wear; erosive wear; anti-corrosion protection methods
Special Issues, Collections and Topics in MDPI journals

Dr. Marcin Adamiak

E-Mail Website
Guest Editor

Materials Research Laboratory, Faculty of Mechanical Engineering, Silesian University of Technology, Konarskiego 18A Str., 44-100 Gliwice, Poland
Interests: engineering materials; composites materials; biomaterials; surface engineering; manufacturing processes and technologies; welding; PVD; powder metallurgy; investigation techniques (electron microscopy, SEM, TEM)
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Antonín Kříž

E-Mail Website
Guest Editor

Department of Materials and Engineering Metallurgy, Faculty of Mechanical Engineering, University of West Bohemia, Univerzitní 22, 306 14 Plzeň, Czech Republic
Interests: welding; laser welding; laser cladding; surface engineering—PVD CVD; manufacturing processes and technologies; powder metallurgy; investigation techniques (scanning electron microscopy; light metallographic microscopy; structural analysis; mechanical testing)

Dr. Tünde Anna Kovács

E-Mail Website
Guest Editor

Department of Materials Technology, Óbuda University, Népszínház u. 8, 1081 Budapest, Hungary
Interests: material sciences; blast protection; explosive welding
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue, "Advanced Welding Technologies, Surfacing, and Thermal Spraying of Modern Engineering Materials", is a forum for the publication of articles allowing an in-depth understanding of the relationship between the structure, properties, and functions in welded joints, as well as surface layers produced using advanced welding technologies and innovative engineering materials. This work includes an overview of various types of welding techniques, including solid-state welding processes, used to join new metal alloys, composites, polymers, and ceramics from different perspectives. The impact of various process parameters, structural morphology, and changes in mechanical properties will be important issues raised in individual chapters. Weld techniques, including laser welding, electron beam welding, plasma welding, ultrasonic welding, diffusion welding, or friction stir welding, will be analysed in terms of creating satisfactory and high-quality welded joints. In addition, the purpose of this Special Issue is to present the latest developments in the field of research regarding innovative technologies and materials for the production of surface layers and coatings resistant to mechanical wear, thermal wear, and corrosion. This part focuses on the influence of a variety of factors in anti-wear surface engineering, on the mechanisms of wear and wear resistance, on the characteristics of different categories of alloy, and on the effects of layers and coatings deposition. Of particular interest are recent developments in advanced materials and processes, including thermal spraying, the plasma and laser surface treatment, surface modification treatments, multilayer structural composites, and nanosurface engineering (with the development of nanoscience and technology), with this Special Issue including original scientific papers shedding light on recent developments in welding and surface technologies.

The main topics of interest include, but are not limited to, the following:

The study of modern welding technologies for dissimilar and difficult-to-weld materials;
The study of modern solid-state welding processes and hybrid welding technologies;
The study of modern surfacing and thermal spraying technologies to produce surface layers and coatings resistant to mechanical and thermal wear;
The study of modern welding processes to produce surfaces and coatings resistant to corrosion;
The study of the structure and mechanical properties of welding joints, surfacing layers, and thermal spray coatings;
The study of wear mechanisms of surface layers and coatings;
Characterization of innovative materials to produce welding joints, surface layers, and thermal spray coatings;
Characterization techniques for innovative welding joints, surface layers, and coatings;
The study of improved economics of welding, surfacing, and thermal spraying.

Dr. Artur Czupryński
Dr. Marcin Adamiak
Prof. Dr. Antonín Kříž
Dr. Tünde Anna Kovács
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

welding
surfacing
thermal spraying
solid-state welding processes
metal alloys
composites
polymers
ceramics
wear resistance
erosion
corrosion

Published Papers (13 papers)

Download All Papers

Research

17 pages, 11441 KiB

Open AccessArticle

Comparison of Wear Resistance of Overlay Welded Layers and Thermal Sprayed Coatings in Real Conditions

by Michał Szymura, Grzegorz Gąsiorek, Artur Czupryński, Waldemar Kwaśny and Viktor Kvasnytskyi

Materials 2023, 16(22), 7215; https://doi.org/10.3390/ma16227215 - 17 Nov 2023

Viewed by 961

Abstract

Tribological tests in real conditions enable obtaining full data on the life of interacting machine parts. This article presents the results of operational tests on the elements of the support ring guidance system in a vertical ball-race mill. The guide and active armour operate under abrasive wear conditions with moderate-impact loads. The wear resistance of elements with overlay welding layers deposited with flux cored wire with a structure of high-alloy chrome cast iron and with a coating flame-sprayed with nickel-based powder was compared. The wear intensity of the overlay weld deposits was much lower than that of the sprayed coatings. The scope of this study also included the analysis of the chemical and phase composition, macro- and microscopic metallographic examinations, and the measurement of the hardness of the deposited layers and coatings. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

11 pages, 6436 KiB

Open AccessArticle

Effect of Surface Modifications on Surface Roughness of Ti6Al4V Alloy Manufactured by 3D Printing, Casting, and Wrought

by János Kónya, Hajnalka Hargitai, Hassanen Jaber, Péter Pinke and Tünde Anna Kovács

Materials 2023, 16(11), 3989; https://doi.org/10.3390/ma16113989 - 26 May 2023

Cited by 5 | Viewed by 1085

Abstract

This work aimed to comprehensively evaluate the influence of different surface modifications on the surface roughness of Ti6Al4V alloys produced by selective laser melting (SLM), casting and wrought. The Ti6Al4V surface was treated using blasting with Al₂O₃ (70–100 µm) and ZrO₂ (50–130 µm) particles, acid etching with 0.017 mol/dm³ hydrofluoric acids (HF) for 120 s, and a combination of blasting and acid etching (SLA). It was found that the optimization of the surface roughness of Ti6Al4V parts produced by SLM differs significantly from those produced by casting or wrought processes. Experimental results showed that Ti6Al4V alloys produced by SLM and blasting with Al₂O₃ followed by HF etching had a higher surface roughness (Ra = 2.043 µm, Rz = 11.742 µm), whereas cast and wrought Ti6Al4V components had surface roughness values of (Ra = 1.466, Rz = 9.428 m) and (Ra = 0.940, Rz = 7.963 m), respectively. For Ti6Al4V parts blasted with ZrO₂ and then etched by HF, the wrought Ti6Al4V parts exhibited higher surface roughness (Ra = 1.631 µm, Rz = 10.953 µm) than the SLM Ti6Al4V parts (Ra = 1.336 µm, Rz = 10.353 µm) and the cast Ti6Al4V parts (Ra = 1.075 µm, Rz = 8.904 µm). Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

25 pages, 33803 KiB

Open AccessArticle

Experimental Comparison of Laser Cladding and Powder Plasma Transferred Arc Welding Methods for Depositing Wear-Resistant NiSiB + 60% WC Composite on a Structural-Steel Substrate

by Marcin Adamiak, Augustine Nana Sekyi Appiah, Radosław Żelazny, Gilmar Ferreira Batalha and Artur Czupryński

Materials 2023, 16(11), 3912; https://doi.org/10.3390/ma16113912 - 23 May 2023

Cited by 5 | Viewed by 1395

Abstract

A Ni-based powder composed of NiSiB + 60% WC was deposited onto a structural-steel substrate using two methods: laser cladding (LC) and plasma powder transferred arc welding (PPTAW). The resulting surface layers were analyzed and compared. Both methods resulted in the precipitation of secondary WC phases in the solidified matrix, but the PPTAW clad exhibited a dendritic microstructure. The microhardness of the clads prepared by both methods was similar, but the PPTAW clad showed higher resistance to abrasive wear compared to the LC clad. The thickness of the transition zone (TZ) was thin for both methods, with a coarse-grain heat-affected zone (CGHAZ) and peninsula-like macrosegregations observed in clads from both methods. The PPTAW clad showed a unique cellular–dendritic growth solidification (CDGS) and a type-II boundary at the TZ attributed to its thermal cycles. While both methods resulted in metallurgical bonding of the clad to the substrate, the LC method exhibited a lower dilution coefficient. The LC method also resulted in a larger HAZ with higher hardness compared to the HAZ of the PPTAW clad. The findings of this study indicate that both methods are promising for antiwear applications due to their wear-resistant properties and metallurgical bonding to the substrate. The PPTAW clad may be particularly useful in applications that require higher resistance to abrasive wear, while the LC method may be advantageous in applications that require lower dilution and larger HAZ. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

22 pages, 41200 KiB

Open AccessArticle

Optimization of Bead Geometry during Tungsten Inert Gas Welding Using Grey Relational and Finite Element Analysis

by Muhammad Hanif, Abdul Hakim Shah, Imran Shah and Jabir Mumtaz

Materials 2023, 16(10), 3732; https://doi.org/10.3390/ma16103732 - 15 May 2023

Viewed by 1601

Abstract

Mild steel welded products are widely used for their excellent ductility. Tungsten inert gas (TIG) welding is a high-quality, pollution-free welding process suitable for a base part thickness greater than 3 mm. Fabricating mild steel products with an optimized welding process, material properties, and parameters is important to achieve better weld quality and minimum stresses/distortion. This study uses the finite element method to analyze the temperature and thermal stress fields during TIG welding for optimum bead geometry. The bead geometry was optimized using grey relational analysis by considering the flow rate, welding current, and gap distance. The welding current was the most influential factor affecting the performance measures, followed by the gas flow rate. The effect of welding parameters, such as welding voltage, efficiency, and speed on the temperature field and thermal stress were also numerically investigated. The maximum temperature and thermal stress induced in the weld part were 2083.63 °C and 424 MPa, respectively, for the given heat flux of 0.62 × 10⁶ W/m². Results showed that the temperature increases with the voltage and efficiency of the weld joint but decreases with an increase in welding speed. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

22 pages, 14891 KiB

Open AccessArticle

Numerical and Physical Simulation of MAG Welding of Large S235JRC+N Steel Industrial Furnace Wall Panel

by Marek Mróz, Robert Czech, Bogdan Kupiec, Andrzej Dec, Marcin Spólnik and Patryk Rąb

Materials 2023, 16(7), 2779; https://doi.org/10.3390/ma16072779 - 30 Mar 2023

Cited by 2 | Viewed by 1235

Abstract

This paper presents the results of a study on the development of a Metal active gas (MAG) welding technology for an industrial furnace component made of steel S235JRC+N with respect to the minimizationof welding deformation. A numerical simulation of the welding process was performed in the first phase of the research. The numerical simulation was carried out with the SYSWELD software. For the numerical simulation of the welding process, the FEM method was used. In the simulation, four variants of restraint of the industrial furnace wall panel elements during the execution of the welding process were investigated. They differed in the number of restraints (model 1–4). It was found that the difference between the maximum mean strain in model 1 and the lowest mean strain in model 4 was only 11%. A physical simulation of the welding process was then performed with a restraint variant according to model 1. The displacement results obtained from the physical simulation of the welding process were compared with the displacement results from the numerical simulation. Discrepancies between numerical and physical simulation displacement values were found. The quality of selected welded joints was also evaluated. Visual testing (VT) and measurements of weld geometries were performed for this purpose. Metallographic tests and hardness measurements were performed to determine of influence of the welding process on the microstructure of the welded joint area, especially the heat affected zone (HAZ). The results obtained confirm the correctness of the assumptions made regarding the technology of manufacturing the furnace wall panels. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

22 pages, 81021 KiB

Open AccessArticle

High-Temperature Corrosion of Flame-Sprayed Power Boiler Components with Nickel Alloy Powders

by Artur Czupryński, Janusz Adamiec, Marcin Adamiak, Marcin Żuk, Antonin Kříž, Claudio Mele and Monika Kciuk

Materials 2023, 16(4), 1658; https://doi.org/10.3390/ma16041658 - 16 Feb 2023

Cited by 2 | Viewed by 1775

Abstract

The development trends in the energy sector clearly indicate an increase in the share of biomass and alternative fuels fed for combustion in power boilers, which results in the imposition of many unfavourable factors and a demanding working environment. During the operation of the energy system, this means a sharp increase in corrosion of the gas-tight pipe walls and coils by the destructive action of chlorine and sulphur. Implementing advanced surface protection in addition to the selection of materials of better quality and resistance to difficult working conditions would significantly reduce their wear by high temperature corrosion. Thermally sprayed coatings offer a great opportunity to protect machine components and energy systems against corrosion, erosion, impact load and abrasive wear. This article presents the test results of high-temperature corrosion resistance of coatings made with Ni-Cr-B-Si and Ni-B-Si alloy powders on a boiler steel substrate. Samples with sprayed coatings were exposed to an atmosphere with a composition of N₂ + 9% O₂ + 0.08% SO₂ + 0.15% HCl at 800 °C for 250, 500, 750 and 1000 h. Tests results of coatings made of Ni-Cr-B-Si alloys subjected to the influence of a corrosive environment showed the formation of a layer of scale on the surface, composed mainly of Cr₂O₃ oxide, which was a passive layer, reducing the rate of corrosion. Coatings sprayed with Ni-B-Si alloys showed significantly lower corrosion resistance. It was found that the developed technology of subsonic flame spraying with powders of the Ni-Cr-B-Si type allows the production of coatings compliant with the requirements of the energy industry, which allows their use as anti-corrosion protection on boiler elements intended for waste disposal and biomass combustion. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

12 pages, 3012 KiB

Open AccessArticle

Arc Characteristics of Ultrasonic-Magnetic Coaxial Hybrid GTAW

by Wenbo Du, Wenlong Li, Yue Li and Chao Chen

Materials 2022, 15(22), 8130; https://doi.org/10.3390/ma15228130 - 16 Nov 2022

Viewed by 1279

Abstract

Ultrasonic-magnetic field coaxial hybrid GTAW(U-M-GTAW) is a new non-melting electrode welding method proposed by combining ultrasonic assisted GTAW(U-GTAW) and magnetic assisted GTAW(M-GTAW) on the regulation characteristics of the GTAW arc. U-M-GTAW introduces ultrasonic and magnetic field effects into GTAW to improve arc characteristics. The orthogonal experiment was designed to investigate the degree of influence of different process parameters on the arc. The degree of influence of ultrasonic power P, radiator height H, magnetic field current C_W, welding current C_W and tungsten electrode height H_T on ΔL₁ (degree of arc root diameter change), ΔL₂ (degree of maximum diameter change) and ΔS (degree of area change) were analyzed. In the parameter range, P has the greatest degree of influence on ΔL₁ and ΔL₂. As all process parameters increase, L₁ shows a tendency to decrease, indicating an increase in the compression of the arc root. ΔL₂ with the increase in P and C_W shows a trend of first decreasing and then increasing. ΔL₂ with the increase in H decreases, indicating that the acoustic radiation force increases, the arc energy increases, and the dark region decreases. The magnetic field current increases, the bottom of the arc expands, and the height of the tungsten electrode increases, the arc dispersion and thus the difference between the dark and luminous regions at the bottom increases, resulting in ΔL₂ with the increase in C_M and H_T increases. C_W has the greatest degree of influence on ΔS. ΔS decreases and then increases as P and H increase, which indicates that the force on acoustic radiation increases and then decreases in the range. An increase in the magnetic field current increases the rotation of the arc, leading to an increase in the arc area. An increase in welding current leads to an increase in arc energy, expansion of the arc morphology, and an increase in ΔS. The tungsten electrode height increases, the arc diverges, the dark region increases, the luminous area decreases, and ΔS increases. Finally, combined with the analysis of ultrasonic field and magnetic field theory, changes in process parameters will affect the force of the arc and thus the arc morphology. The U-M-GTAW arc under the action of acoustic radiation force, the plasma flow is shifted in the direction of the arc axis, and the arc contraction, under the action of magnetic field force to generate circumferential current, the arc undergoes periodic rotation, which improves GTAW arc characteristics. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

17 pages, 6110 KiB

Open AccessArticle

Calorimetric Method for the Testing of Thermal Coefficients of the TIG Process

by Marek Mróz, Antoni Władysław Orłowicz, Magdalena Lenik, Andrzej Trytek and Mirosław Tupaj

Materials 2022, 15(20), 7389; https://doi.org/10.3390/ma15207389 - 21 Oct 2022

Viewed by 1009

Abstract

This paper presents an original design of a test apparatus for calorimetric measurements of arc efficiency η and melting efficiency η_m in welding processes. The construction and principle of operation of a new flow calorimeter are described, as well as the method for determining the η and η_m values in the process of the surface melting of aluminium–silicon alloy casting surfaces with a concentrated heat flux generated by the TIG (Tungsten Inert Gas) method. The results obtained indicate the advisability of using calorimetric testing to assess the arc efficiency of welding processes. It was demonstrated that changing the welding current and arc scanning speed, as well as changing the chemical composition of the silumin, has an effect on the arc efficiency value η. This has the effect of introducing a different amount of heat into the area of the heated material. The consequence of this is a change in the value of the melting efficiency η_m, which results in a change in the width and depth of the surface melting areas, through this, the cooling conditions of the material. As is well known, this will affect the microstructure of the welds and the width and microstructure of the heat-affected zone, and thus the performance of the welded joints. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

14 pages, 3969 KiB

Open AccessArticle

Microstructures and Properties Investigation on DP980 Dual-Phase Steel CMT + P Welded Joints

by Yan Liu, Zhaozhen Liu, Yongman Chen, Chunlin He, Ao Liu and Xiaoang Liu

Materials 2022, 15(17), 5880; https://doi.org/10.3390/ma15175880 - 25 Aug 2022

Cited by 1 | Viewed by 1493

Abstract

The increasing demand for the lightweight production of advanced high-strength steel puts forward higher requirements for the quality of welded joint forming. The common CMT welding process has certain limitations and is difficult to meet the needs of lightweight manufacturing. In this study, the CMT + P welding technology was used to weld the DP980 dual-phase steel plate with 1.2 mm thickness. The ER120S-G welding wire was used as the filling material to conduct a 70° angle lap welding experiment. The effects of wire feeding speed (3 m/min~5 m/min) and welding speed (350 mm/min~600 mm/min) on the forming, microstructures, and mechanical properties of DP980 dual-phase steel welded joints were analyzed. The results show that the CMT + P welding process can produce lap weldments with good formability and properties. The welded joints can be divided into the weld zone, the HAZ, and the base metal zone, where the HAZ can be divided into the coarse-grained zone and the softened zone. The role of the elements Ni and Si is to promote the production of martensite and to increase the ferrite strength in welded joints. As the wire feeding speed increases, the grain size of the coarse grain zone in the HAZ increases from 31.90 μm to 50.93 μm; while the welding speed increases, the grain size of the coarse grain zone decreases from 45.48 μm to 35.73 μm. The average microhardness of the weld zone is 420 HV. In contrast, the average microhardness of the softening zone in HAZ is reduced to 250 HV. When the wire feeding speed is 4 m/min and the welding speed is 550 mm/min, the tensile properties of the weldment are optimal, its tensile strength can reach 973 MPa, and the tensile fracture is ductile fracture. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

11 pages, 10882 KiB

Open AccessArticle

Rebuilding of Turbocharger Shafts by Hardfacing

by Bogdan Kupiec, Zenon Opiekun and Andrzej Dec

Materials 2022, 15(16), 5761; https://doi.org/10.3390/ma15165761 - 20 Aug 2022

Viewed by 1903

Abstract

This paper presents the results of structural tests and hardness measurements of rebuilding coatings manually applied by the gas tungsten arc welding (GTAW) method on damaged surfaces of steel shafts of turbochargers of automotive engines. Single- and double-layer coatings were applied in an argon atmosphere by fusing a 1.2 mm diameter wire with a Fluxofil M58 flux core, using a current of 35A and an arc voltage of 8–9 V. The hardfacing resulted in coatings with a martensitic–bainitic structure with fine dispersed carbides rich in M23C6-type chromium. The hardness of the coatings on the rebuilt shafts averaged from about 740HV5 for the single-layer coating to about 770HV5 for the double-layer coating and was two times higher than the hardness of the tempered shafts without coatings. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

13 pages, 5260 KiB

Open AccessArticle

Problems of HLAW Hybrid Welding of S1300QL Steel

by Bogdan Kupiec, Michał Urbańczyk, Magdalena Radoń and Marek Mróz

Materials 2022, 15(16), 5756; https://doi.org/10.3390/ma15165756 - 20 Aug 2022

Cited by 2 | Viewed by 1469

Abstract

This paper presents the results of tests on the fabrication of welded joints in S1300QL steel according to the requirements of ISO 15614-14 and ISO 12932. The butt-welded joint without bevel was made from 350 × 150 × 8 mm sheets. The welding process was carried out at the hybrid welding (laser–MAG) station. MAG means metal active gas. The test welded joints were subjected to non-destructive and destructive testing. Visual and radiographic examinations were carried out. The distribution of HV10 hardness was determined in the weld, the heat-affected zone, and the base material. The microstructure of these areas was also analysed for the presence of hard and brittle hardening products and non-metallic inclusions. Tensile strength and yield strength, as well as bending strength, were assessed in the mechanical property tests. The impact test was performed in accordance with ISO 9016. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

22 pages, 15305 KiB

Open AccessArticle

Powder Plasma Transferred Arc Welding of Ni-Si-B+60 wt%WC and Ni-Cr-Si-B+45 wt%WC for Surface Cladding of Structural Steel

by Augustine Nana Sekyi Appiah, Oktawian Bialas, Artur Czupryński and Marcin Adamiak

Materials 2022, 15(14), 4956; https://doi.org/10.3390/ma15144956 - 16 Jul 2022

Cited by 14 | Viewed by 3189

Abstract

Increasing demand for sustainable approaches to mining and raw material extraction, has prompted the need to explore advanced methods of surface modification for structural steels used in the extractive industry. The technology of powder plasma transferred arc welding (PPTAW), was used in this study as a surface modification technique to improve upon the abrasive wear resistance of structural steel grade EN S355. PPTAW process parameters, namely, plasma transferred arc (PTA) current and plasma gas flow rate (PGFR), were varied, and the effects of the variation were studied and used as criteria for selecting optimum conditions for further studies and parametric reproducibility. Two metal matrix composite (MMC) powders were used in the process, having compositions of Ni-Si-B+60 wt%WC (PG) and Ni-Cr-Si-B+45 wt%WC (PE). Microstructural observation under a scanning electron microscope (SEM) revealed a dendritic, multi-directional microstructure consisting of partially dissolved primary tungsten carbide particles and secondary tungsten carbide precipitates within the MMC solid solution. The hardness of the surface layers was higher than that of a reference AR400 steel by more than 263 HV. Final surface layers obtained from the MMC powders had abrasive wear resistance up to 5.7 times that of abrasion-resistant reference AR400 steel. Alloying the MMC matrix with chromium increased the hardness by 29.4%. Under the same process conditions, MMC powder with 60 wt% WC reinforcement had better abrasive wear resistance by up to 45.8% more than the MMC powder with 45 wt% WC. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

17 pages, 9563 KiB

Open AccessArticle

High-Power Diode Laser Surface Transformation Hardening of Ferrous Alloys

by Artur Czupryński, Damian Janicki, Jacek Górka, Andrzej Grabowski, Bernard Wyględacz, Krzysztof Matus and Wojciech Karski

Materials 2022, 15(5), 1915; https://doi.org/10.3390/ma15051915 - 4 Mar 2022

Cited by 2 | Viewed by 1533

Abstract

A high-power direct diode laser (HPDDL) having a rectangular beam with a top-hat intensity distribution was used to produce surface-hardened layers on a ferrous alloy. The thermal conditions in the hardened zone were estimated by using numerical simulations and infrared (IR) thermography and then referred to the thickness and microstructure of the hardened layers. The microstructural characteristics of the hardened layers were investigated using optical, scanning electron and transmission electron microscopy together with X-ray diffraction. It was found that the major factor that controls the thickness of the hardened layer is laser power density, which determines the optimal range of the traverse speed, and in consequence the temperature distribution in the hardened zone. The increase in the cooling rate led to the suppression of the martensitic transformation and a decrease in the hardened layer hardness. The precipitation of the nanometric plate-like and spherical cementite was observed throughout the hardened layer. Full article

(This article belongs to the Special Issue Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials)

► Show Figures

Figure 1

Journal Menu

Journal Browser

Advanced Technologies of Welding, Surfacing, and Thermal Spraying of Modern Materials

Share This Special Issue

Special Issue Editors

Special Issue Information

Keywords

Published Papers (13 papers)

Research

Further Information

Guidelines

MDPI Initiatives

Follow MDPI