Search Results (479)

Laser cladding is an essential method for strengthening and restoring component surfaces. To increase its efficacy and provide a reliable surface treatment technique, it is necessary to optimize process parameters, enhance material adhesion, and guarantee high-quality, reliable coatings. These measures help to extend the lifespan of components. In this study, the surfaces of AISI 904L stainless steel samples were cladded to prepare various Co-based composite coatings with single and multiple layers reinforced with WC–CoCr–Ni powder. The phases within the newly developed layers were investigated using X-ray Diffraction (XRD), while the microstructure was examined using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDX). Further tests were performed to assess the hardness, wear resistance and corrosion performance of the deposited coatings. Analyzing and comparing the coatings, it was observed that the coating performance increased with increasing thickness and generally due to a lower amount of Fe present within the microstructure. Full article

This paper investigates the influence of substrate grain size on the behavior of a multilayer CrN/CrAlN coating, with the bilayer thickness varying across the cross-section in the range of 200–1000 nm. The substrate tools were made of WC-Co sintered carbide with three different grain sizes. The coatings were subjected to mechanical and tribological tests to assess their performance, including nanohardness, scratch resistance, and tribological testing. The coating’s roughness was measured using a 2D profilometer. Additionally, the chemical composition and surface morphology were analyzed using Scanning Electron Microscopy (SEM) and Energy Dispersive X-Ray Spectroscopy (EDX). The durability tests were performed on an industrial CNC machine tool on the particleboard. The results revealed that tools with ultra-fine nano-grain (S) and micro-grain (T) WC-Co substrates exhibited a significant increase in tool durability by 28% and 44%, respectively. Significant differences in the microgeometry of the substrate U, especially in relation to the tool based on substrate S, explain the lack of improvement in its durability despite the use of a multilayer coating. Full article

The high-temperature and hot corrosion behavior of Diamalloy 2002 coatings with a WC/Co–NiCrFeBSiC composite structure applied to a 316 L stainless steel surface using the atmospheric plasma spraying (APS) method was investigated. The coatings were held at 900 °C in air for 5, 25, 50, and 100 h and in a molten salt bath of Na₂SO₄ + V₂O₅ at 900 °C for 1, 3, and 5 h. SEM, EDS, and XRD analyses revealed that the oxide layer on the surface thickened with increasing temperature and corrosion duration, forming NiO, Cr₂O₃, and mixed metal oxides. These oxide phases created a protective barrier effect by limiting diffusion between the coating and the substrate. Despite a slight increase in porosity and minor WC dissolution under long-term oxidation conditions, the coatings maintained their structural integrity up to 900 °C, demonstrating significant resistance to high-temperature oxidation and molten salt corrosion. These results demonstrate that Diamalloy 2002 coatings provide an effective surface protection solution in abrasive and oxidizing high-temperature environments. Full article

Premature deterioration of concrete structures in coastal areas requires a careful evaluation based on durability criteria. Electrical Resistivity (ER) serves as a valuable indicator of concrete durability, as it reflects how easily aggressive agents can penetrate its pores. This testing method offers several advantages; it is non-destructive, rapid, and more cost-effective than the chloride permeability test (RCPT). Furthermore, durable concrete typically necessitates larger quantities of cement, which contradicts the goals of sustainable concrete development. Thus, a significant challenge is to create concrete that is both durable and sustainable. This research explores the effects of pozzolanic additives, specifically Volcanic Ash (VA) and Sugarcane Bagasse Ash (SCBA), on the electrical resistivity of eco-friendly concretes exposed to the coastal conditions of the Gulf of Mexico. The electrical resistivity (ER) was measured at intervals of 3, 7, 14, 21, 28, 45, 56, 90, and 180 days across 180 cylinders, each with dimensions of 10 cm × 20 cm. The sustainability of the concrete was evaluated based on its energy efficiency. Three types of mixtures were developed using the ACI 211.1 method, maintaining a water-to-cement (w/c) ratio of 0.57 with CPC 30 R RS cement and incorporating various additions: (1) varying percentages of VA (2.5%, 5%, and 7.5%), (2) SCBA at rates of 5%, 10%, and 15%, and (3) ternary mixtures featuring VA-SCBA ratios of 1:1, 1:2, and 1:3. The findings indicated an increase in ER of up to 37% and a reduction in CO₂ emissions ranging from 4.2% to 16.8% when compared to the control mixture, highlighting its potential for application in structures situated in aggressive environments. Full article

This paper investigates WC-10Co4Cr coatings on 4340 steel prepared by conventional HVOF and novel cold spraying (CS) under optimal process parameters to address low wear resistance. The results show that the CS WC-10Co4Cr coating porosity is less than 0.1%, while the HVOF WC-10Co4Cr coating porosity is about 0.3%. The WC phase in the CS coating did not change, whereas the WC phase in the HVOF coating underwent decarburization and a new W₂C phase was formed. The microhardness of the CS WC-10Co4Cr coating reaches 1617.2 HV_0.3, which is about 50% higher than that of HVOF WC-10Co4Cr coating of 1061.3 HV_0.3. The sliding wear rate of the CS WC-10Co4Cr coatings is 0.17 × 10⁻⁵ μm³/N·m, which is 40% of that of the HVOF coatings. The CS coating’s fretting wear rate is 1.28 μm³/N·m, which is 40% faster than that of HVOF coating. However, the bond strength of the CS WC-10Co4Cr coating (35 MPa) is lower than that of the HVOF coating (73.5 MPa). Overall, the WC-10Co4Cr coatings prepared by the CS process have higher hardness, denser coating microstructure, and better sliding wear resistance than those prepared by the conventional HVOF process. Full article

Machining hard metals presents various challenges, especially with materials like WC-Co, known for their exceptional hardness and wear resistance, making them ideal for cutting tools. Among machining methods, Electrical Discharge Machining (EDM) stands out for its ability to machine hard materials with no mechanical damage, which is critical for machining fragile components. For form shape machining symmetrical parts like WC-Co bars, electrical discharge turning (EDT) could be applied. Despite its potential, limited research exists on deep form turning of hard metals like WC-Co using EDT. This study addresses that gap by comparing the final geometrical outcomes of two EDT setups: vertical and horizontal tool electrode configurations. Additionally, the impact of workpiece rotational speed on surface quality was examined. Results showed that the vertical tool electrode setup produced more accurate geometries and smoother surfaces. Furthermore, increasing the workpiece’s rotational speed improved flushing efficiency, resulting in reduced surface roughness and a cleaner machined surface. Full article

The increasing reliance on conventional coatings such as WC-Co raises serious environmental and health concerns due to the toxicity of cobalt and the ecological footprint of these materials. To address this challenge, the present study explores the development of eco-friendly multifunctional coatings via the Plasma Spray (PS) process, using titanium (Ti), silicon carbide (SiC), and tungsten carbide-cobalt (WC-Co) mixtures as alternative feedstocks. Steel substrates were coated under different deposition strategies (powder mixing, layer-by-layer) and current settings (800-900 A). The coatings were characterized by scanning electron microscopy (SEM/EDX), 3D profilometry, sliding wear testing, and potentiodynamic corrosion measurements. Results showed that Ti-WC (mix, 900 A) and Ti-SiC (layer, 900 A) coatings achieved the most favorable performance, combining excellent adhesion, uniform coverage, reduced porosity, and improved resistance to wear and corrosion compared to conventional Cr₂O₃ coatings. Notably, Ti-WC coatings provided surface roughness values comparable to Cr₂O₃, while significantly lowering the environmental impact. These findings demonstrate that PS-based Ti-WC and Ti-SiC systems can serve as sustainable and high-performance alternatives for protective applications in harsh environments, particularly in marine industries, supporting the transition toward coatings with reduced ecological footprint. Full article

In this study, we investigated the tribological properties of various additives (lubricity, friction modifiers, anti-wear and extreme pressure) in a highly volatile paraffinic base oil formulated for stamping applications, using a newly developed methodology for tribological testing. The investigation focused on the short-term (10 cycles) and long-term (10,000 cycles) effects of the different additive mixtures on friction and wear behaviour. It was found that the performance of the additive mixtures evolves with sliding time, which is due to changes in contact conditions: the transfer of the Fe film from the steel sheet to the WC-Co surface increases the contact area, which in turn leads to a significant reduction in contact pressure and changes the activation of tribofilm formation. The presence of tribofilms influences the amount and size of the contact area and reduces the adhesion between the contact surfaces. Among the conventional additives, sulphurised additive mixtures show stable performance under both short and long-term conditions, while more aggressive chlorinated additive mixtures perform well in the short term, but their performance decreases with prolonged sliding. Importantly, the additives with a decreasing environmental impact outperformed the conventional additives under long-term conditions: the less harmful phosphorus-based mixture outperformed the sulphurised mixtures in terms of wear properties, while the performance of environmentally acceptable polyol ester was particularly encouraging, exhibiting the lowest friction coefficient (~0.11, compared with ~0.12 for S-oil and 0.14 for S-ester) and the second lowest wear coefficient (~1.1 × 10⁻¹ mm³/Nm compared with ~1.5 × 10⁻¹ mm³/Nm for S-ester). Overall, the polyol ester reduced the coefficient of friction by approximately 8 to 21% compared to sulphurised additive mixtures, and its wear coefficient was also about 27% lower. Full article

Introduction: Over the last two decades, obesity has evolved into a global pandemic. Environmental pollutants, as endocrine disruptors, may play a key role in the development of obesity. The study aimed to assess the relationship between the concentration of certain trace elements and heavy metals (Cu, Zn, Mn, Co, Cr and Fe) and ferritin in blood serum, with anthropometric and physiological parameters associated with overweight and obesity in individuals following myocardial infarction and without a previous myocardial infarction. Method: The study was conducted in a group of 146 respondents divided into two groups: a study group (SG) of patients that had a history of myocardial infarction (n = 74) and a control group (CG) of patients that had no history (n = 72). The inductively coupled plasma mass spectrometry was employed to assess the concentration of trace elements and heavy metals. Measurements were taken to determine the anthropometric indices associated with overweight and obesity. Results: In the SG, there was a positive correlation between Cr concentration and body adiposity index (BAI) and a negative correlation between Zn, Zn/Cu, and ferritin level and percentage body fat (FM%). In the CG, there was a positive correlation between Zn concentration and WHtR and between ferritin level and BMI, WC, WHR and WHtR. Additionally, a negative correlation was found between Mn concentration and WHR and ferritin level and BAI and FM%. Conclusions: This study found a link between certain blood concentrations of trace elements and heavy metals and anthropometric and physiological indices associated with overweight and obesity. It, therefore, has substantial implications for public health. Full article

The present contribution showcases the potential brake emission reduction with Cr₂O₃ (chromium oxide) and WC-CoCr (tungsten carbide–chromium–cobalt) rotor coatings, as realized in our joint public–private research consortium. Particulate matter (PM) emissions from automotive braking systems have been characterized using a pin-on-disc tribometer equipped with particle measurement devices: a CPC (Condensation Particle Counter), an APS (Aerodynamic Particle Sizer), an SMPS (Scanning Mobility Particle Sizer), and a PM_2.5 sampling unit. Brake pad samples made from the same low-steel friction material were tested against a grey flake cast iron disc and two types of custom coated discs: a Cr₂O₃-coated disc and a WC-CoCr-coated disc. The friction pairs were investigated at a constant contact pressure of 1.2 MPa while the sliding velocity varied during the test, starting with 25 sequences at 3.6 m/s, followed by 19 sequences at 6.1 m/s, and finishing with 6 sequences at 11.2 m/s. The test results show encouraging 64% to 84% reductions in particle number (PN) emissions between 4 nm and 3 µm and 84% to 95% reductions in mass emissions (PM_2.5) thanks to the respective coated discs. SEM-EDXS (Scanning Electron Microscopy and Energy Dispersive X-ray Spectroscopy) analyses show that the hardness and roughness of the discs, the chemical reactivity (oxidation), and the abrasiveness of the three friction pairs are parameters that might explain this reduction in emission. Full article

The high density of the internal structure of new-generation cementitious composites, such as high-performance and ultra-high-performance concretes, necessitates the use of advanced methods for evaluating their transport properties, particularly those employing a gaseous medium. The developed gas permeability method for cement pastes, based on a modified RILEM-Cembureau approach, has proven to be highly accurate, reliable, and extremely sensitive to changes in the porosity characteristics of such composites. The article contains the results of a study of the mass transport capabilities of blended cement pastes, characterised by variable water–cement ratios. Two types of cements were used in the study: with the addition of fly ash and blast furnace slag. Ordinary Portland cement was used as the reference binder. The tests were conducted after long-term curing under natural conditions, i.e., after 90 days and 2 years. The assessment of open porosity was carried out through three techniques: helium pycnometry, mercury intrusion porosimetry, and water saturation. Permeability, on the other hand, was measured using a customized approach tailored for uniform paste materials. Microstructural changes were also analysed in the context of natural hydration carbonation progress. The results presented allowed a quantitative description of the effects of the w/c ratio, the presence of additives, and the progress of hydration and carbonation on the porosity of pastes and their permeability to gas flow. The two-year curing period of the pastes exposed to natural CO₂ resulted in a reduction of the permeability coefficient k ranging from 11% to 74%, depending on the type of cement and the water-to-cement (w/c) ratio. This decrease was caused by the continued progress of hydration and simultaneous carbonation. The results of the research presented are of interest from both an engineering and scientific point of view in the context of long-term microstructural changes and the mass transport abilities of cement pastes associated with these processes. The extensive range of materials compositions investigated makes it possible to analyse the durability and tightness of many cementitious composites over long periods of service. Full article

HVAF WC-10Co-4Cr coating has been applied to the extreme wear protection of lightweight titanium alloy workpieces. However, the new generation of lightweight titanium alloy inner bore wear-resistant workpieces is faced with strong wear and instantaneous high-temperature airflow erosion during service, which requires a WC-10Co-4Cr wear-resistant coating with low surface roughness, high thickness and high toughness. In addition, its small diameter inner hole also requires the rapid heating, melting and acceleration performance of sprayed powder during spraying. At present, the finest spraying powder used in this system is generally in the range of 5–15 μm, which faces difficulties in meeting the above requirements. In order to solve this problem, the preparation of 2–10 μm spherical spray powder was studied though a spray granulation experiment, and the change law of powder morphology with the solid content of pre-spray slurry was explored. The suitable binder was selected through a slurry sedimentation test and viscosity test, so that the gunable solid content of the pre-sprayed slurry was reduced from 60 wt.% to 12.5% by weight, which significantly reduces the particle size of the powder obtained by spray granulation. When the solid content of pre-sprayed slurry is 12.5 wt.%, sodium carboxymethyl cellulose (CMC-Na) is selected as the binder, and the binder content is 2 wt.%, the particle size range of powder obtained by spray granulation process reaches 2–10 μm, and the median particle size reaches 5 μm. After heat treatment, the powder is spherical and dense inside. The research results provide technical support for preparing high-performance ultrafine WC-10Cr-4Co spherical powder with wear-resistant coating for light titanium alloy. Full article

The spray drying of hard metal (WC-Co) powders is a critical step in the production of high-performance cutting and wear-resistant tools. Traditionally, organic solvents such as ethanol or acetone are employed in this process, despite posing substantial health, safety, and environmental risks. This study investigates a sustainable alternative by replacing organic solvents with water in the spray-drying process. We present a comparative analysis of granule morphology, flowability, and final mechanical properties between solvent-based and water-based routes. The water-based approach achieved a d₅₀ of 99 µm, flow time of 27.8 s, and apparent density of 3.18 g/cm³, closely matching the solvent-based values (d₅₀ = 93 µm, flow = 28.4 s, and ρ = 3.14 g/cm³). Hardness (HV30 ≈ 1650) and microstructure were equivalent across both routes, confirming that the substitution does not compromise performance. The water-based process also offers an estimated reduction of over 50% in CO₂ emissions compared to traditional methods. These findings support the feasibility of water-based granulation as a viable, scalable, and safer route for WC-Co powder production, in alignment with dematerialization, circular material use, and the broader goals of sustainable development. Full article

In order to enhance the performance of 20# steel, this study successfully fabricated AlCoCrFeNi high-entropy alloy coatings with different WC contents (x = 0, 10, 20, 30 wt%) on its surface using plasma cladding technology. The effects of WC content on the microstructure, mechanical properties, and corrosion resistance of the coatings were systematically investigated. The results indicate that without WC addition, the coating consists of a dual-phase structure comprising BCC and FCC phases. With the incorporation of WC, the FCC phase disappears, and the coating evolves into a composite structure based on the BCC matrix, embedded with multiple carbide phases such as W₂C, M₇C₃, M_xC_γ, and Co₆W₆C. These carbides are predominantly distributed along grain boundaries. As the WC content increases, significant grain refinement occurs and the volume fraction of carbides rises. The coating exhibits a mixed microstructure of equiaxed and columnar crystals, with excellent metallurgical bonding to the substrate. The microhardness of the coating increases markedly with higher WC content; however, the rate of enhancement slows when WC exceeds 20 wt%. The hardness of 1066.36 HV is achieved at 30 wt% WC. Wear test results show that both the friction coefficient and wear rate first decrease and then increase with increasing WC content. The optimal wear resistance is observed at 20 wt% WC, with a friction coefficient of 0.549 and a wear mass loss of only 0.25 mg, representing an approximately 40% reduction compared to the WC-free coating. Electrochemical tests demonstrate that the coating with 20 wt% WC facilitates the formation of a dense and stable passive film in NaCl solution, effectively inhibiting Cl⁻ ion penetration. This coating exhibits the best corrosion resistance, characterized by the lowest corrosion current density of 1.349 × 10⁻⁶ A·cm⁻² and the highest passive film resistance of 2764 Ω·cm². Full article

A cost-effective Fe-Cr-Mo-B-Si-C metamorphic alloy (HXA5) was newly designed and fabricated as coating material using the high-velocity oxygen fuel (HVOF) thermal spray process, and its microstructure and dry wear resistance were investigated in comparison with a conventional HVOF WC-12Co coating. The HXA5 coating material consisted of a splat area and un-melted powder area. The splat area contained metallic glass, (Cr,Fe)₂B, Cr₂B, and minor Fe-based BCC phases, and the un-melted powder area was composed of Fe-based BCC, (Cr,Fe)₂B, and Cr₂B phases. Room-temperature wear tests revealed that HVOF HXA5 coating material exhibited wear resistance comparable to HVOF WC-12Co coating over ~8.4 km sliding and even superior performance at high-stress wear conditions. This superior wear behavior of HXA5 coating material was attributed to the minimal hardness difference between the metallic glass and boride, the plasticity of the metallic glass, and the formation of a lubricating tribofilm. The wear mechanisms and the influence of alloying elements on glass-forming ability were also discussed. Full article