Optimization of the Arc Spraying Process Parameters of the Fe-Base Mn-Si-Cr-Mo-Ni Coatings for the Best Wear Performance

In this paper, the use of Fe-base Mn-Si-Cr-Mo-Ni and Fe-base Mn-Si-Cr wires for thermal arc spraying is presented. For this purpose the mechanical and physical properties of coatings were evaluated. The quality of the coating's was dependent on the selected equipment, spray materials, technological parameters of the spray and spray technology. The aim was to qualify and optimize the parameters for spray coating to get the best coatings properties with good tribological properties. All coatings were deposited on mild steel S235JR substrates. Two experimental cored wires of unique chemical composition -STEIN-MESYFIL 932 V and STEIN-MESYFIL 954 V - were used for thermal arc spraying. The wires of 1.6 mm diameter were used for the surfacing material. Hardness, porosity and oxide measurements were used to verify the spray parameters and analyze the coatings. Rubber wheel test, which is based on the standard ASTM G65, was used. Dry-sand, rubber-wheel procedure according ASTM G65 was used to investigate low stress abrasion, whereas for high stress abrasion investigations a rubber wheel was used. This experiment was carried out by changing the speed of disc friction, travel distance and measuring the mass loss of surface friction. Miller Test according to ASTM G75-95 Standard was carried out in experiment with friction. The samples were immersed in water with corundum and polished with 22 N load, for 8 hours. Furthermore a correlation was performed between the spraying current and voltage parameter. The coatings' cross sections were examined using scanning electron microscope (SEM) and optical microscopy. The influence of the composite components of the coatings' microstructure, such as porosity, microhardness, oxide inclusions, on the tribological properties of thermal sprayed coatings is discussed in this paper.