Structure and properties of powder gas-plasma coatings based on nickel
The development of modern technology requires a constant increase in reliability and durability of products. Widely used in the practice of domestic and foreign engineering coatings from electrolytic chromium for several hundred hours are triggered, they are unsatisfactorily working on friction and...
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Національний науковий центр «Харківський фізико-технічний інститут» НАН України
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nasplib_isofts_kiev_ua-123456789-1956582025-02-09T22:31:42Z Structure and properties of powder gas-plasma coatings based on nickel Структура і властивості порошкових газоплазмових покриттів на основі нікелю Hlushkova, D.B. Bagrov, V.A. Demchenko, S.V. Volchuk, V.M. Kalinin, O.V. Kalinina, N.E. Physics of radiation and ion-plasma technologies The development of modern technology requires a constant increase in reliability and durability of products. Widely used in the practice of domestic and foreign engineering coatings from electrolytic chromium for several hundred hours are triggered, they are unsatisfactorily working on friction and wear at high temperatures. The subject of the study were powder materials based on nickel PG-SR3 and PG-SR4. The work is devoted to the study of the formation of gas-plasma coatings on parts of the cylinder-piston group of internal combustion engines using self-fluxing powders based on nickel, as well as the structure and properties change after coating sputtering, its reflow, subsequent hardening. The purpose of this work is to study powder materials applied to the working surfaces of piston rings by gas-thermal spraying. The object of the study are processes of formation of the structure and properties of coatings from powder materials. The presence in the deposited layer of a solid solution based on nickel, carbide phase, borides of chromium and nickel, chromium silicides is established. The greatest macro- and microhardness is possessed by fused layers containing the greatest number of strengthening phases. The conducted researches and industrial tests allowed to introduce the coating into production. Розвиток сучасної техніки потребує постійного підвищення надійності та довговічності виробів. Широко застосовувані в практиці вітчизняного та зарубіжного машинобудування покриття з електролітичного хрому за кілька сотень годин спрацьовуються, вони незадовільно працюють на тертя та зношування за високих температур. Предметом дослідження були порошкові матеріали на основі нікелю ПГ-СР3 та ПГ-СР4. Робота присвячена дослідженню формування газоплазмових покриттів на деталях циліндропоршневої групи двигунів внутрішнього згоряння з використанням самофлюсованих порошків на основі нікелю, а також зміні структури та властивостей після напилення покриття, його оплавлення, наступного загартування. Мета роботи – дослідження порошкових матеріалів, які нанесені на робочі поверхні поршневих кілець газотермічним напиленням. Об’єктом дослідження є процеси формування структури та властивостей покриттів із порошкових матеріалів. Встановлено наявність у напиленому шарі твердого розчину на основі нікелю, карбідної фази, боридів хрому та нікелю, силіцидів хрому. Найбільшу макро- і мікротвердість мають оплавлені шари, що містять найбільшу кількість зміцнювальних фаз. Проведені дослідження та промислові випробування дозволили впровадити покриття у виробництво. 2022 Article Structure and properties of powder gas-plasma coatings based on nickel / D.B. Hlushkova, V.A. Bagrov, S.V. Demchenko, V.M. Volchuk, O.V. Kalinin, N.E. Kalinina // Problems of Atomic Science and Technology. — 2022. — № 4. — С. 125-130. — Бібліогр.: 13 назв. — англ. 1562-6016 PACS: 81.15.-z, -07.-b; 68.65.-k, -55.Nq DOI: https://doi.org/10.46813/2022-140-125 https://nasplib.isofts.kiev.ua/handle/123456789/195658 en Вопросы атомной науки и техники application/pdf Національний науковий центр «Харківський фізико-технічний інститут» НАН України |
| institution |
Digital Library of Periodicals of National Academy of Sciences of Ukraine |
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DSpace DC |
| language |
English |
| topic |
Physics of radiation and ion-plasma technologies Physics of radiation and ion-plasma technologies |
| spellingShingle |
Physics of radiation and ion-plasma technologies Physics of radiation and ion-plasma technologies Hlushkova, D.B. Bagrov, V.A. Demchenko, S.V. Volchuk, V.M. Kalinin, O.V. Kalinina, N.E. Structure and properties of powder gas-plasma coatings based on nickel Вопросы атомной науки и техники |
| description |
The development of modern technology requires a constant increase in reliability and durability of products. Widely used in the practice of domestic and foreign engineering coatings from electrolytic chromium for several hundred hours are triggered, they are unsatisfactorily working on friction and wear at high temperatures. The subject of the study were powder materials based on nickel PG-SR3 and PG-SR4. The work is devoted to the study of the formation of gas-plasma coatings on parts of the cylinder-piston group of internal combustion engines using self-fluxing powders based on nickel, as well as the structure and properties change after coating sputtering, its reflow, subsequent hardening. The purpose of this work is to study powder materials applied to the working surfaces of piston rings by gas-thermal spraying. The object of the study are processes of formation of the structure and properties of coatings from powder materials. The presence in the deposited layer of a solid solution based on nickel, carbide phase, borides of chromium and nickel, chromium silicides is established. The greatest macro- and microhardness is possessed by fused layers containing the greatest number of strengthening phases. The conducted researches and industrial tests allowed to introduce the coating into production. |
| format |
Article |
| author |
Hlushkova, D.B. Bagrov, V.A. Demchenko, S.V. Volchuk, V.M. Kalinin, O.V. Kalinina, N.E. |
| author_facet |
Hlushkova, D.B. Bagrov, V.A. Demchenko, S.V. Volchuk, V.M. Kalinin, O.V. Kalinina, N.E. |
| author_sort |
Hlushkova, D.B. |
| title |
Structure and properties of powder gas-plasma coatings based on nickel |
| title_short |
Structure and properties of powder gas-plasma coatings based on nickel |
| title_full |
Structure and properties of powder gas-plasma coatings based on nickel |
| title_fullStr |
Structure and properties of powder gas-plasma coatings based on nickel |
| title_full_unstemmed |
Structure and properties of powder gas-plasma coatings based on nickel |
| title_sort |
structure and properties of powder gas-plasma coatings based on nickel |
| publisher |
Національний науковий центр «Харківський фізико-технічний інститут» НАН України |
| publishDate |
2022 |
| topic_facet |
Physics of radiation and ion-plasma technologies |
| url |
https://nasplib.isofts.kiev.ua/handle/123456789/195658 |
| citation_txt |
Structure and properties of powder gas-plasma coatings based on nickel / D.B. Hlushkova, V.A. Bagrov, S.V. Demchenko, V.M. Volchuk, O.V. Kalinin, N.E. Kalinina // Problems of Atomic Science and Technology. — 2022. — № 4. — С. 125-130. — Бібліогр.: 13 назв. — англ. |
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Вопросы атомной науки и техники |
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ISSN 1562-6016. ВАНТ. 2022. №4(140) 125
https://doi.org/10.46813/2022-140-125
UDC 621.891
STRUCTURE AND PROPERTIES OF POWDER GAS-PLASMA
COATINGS BASED ON NICKEL
D.B. Hlushkova1, V.A. Bagrov1, S.V. Demchenko1,
V.M. Volchuk2, O.V. Kalinin2, N.E. Kalinina3
1Kharkiv National Automobile and Highway University, Kharkiv, Ukraine
E-mail: diana@khadi.kharkov.ua;
2Prydnіprovska State Academy of Civil Engineering and Architecture,
Dnipro, Ukraine;
3Oles Honchar Dnipro National University, Dnipro, Ukraine
E-mail: diana.borisovna@gmail.com
The development of modern technology requires a constant increase in reliability and durability of products.
Widely used in the practice of domestic and foreign engineering coatings from electrolytic chromium for several
hundred hours are triggered, they are unsatisfactorily working on friction and wear at high temperatures. The subject
of the study were powder materials based on nickel PG-SR3 and PG-SR4. The work is devoted to the study of the
formation of gas-plasma coatings on parts of the cylinder-piston group of internal combustion engines using self-
fluxing powders based on nickel, as well as the structure and properties change after coating sputtering, its reflow,
subsequent hardening. The purpose of this work is to study powder materials applied to the working surfaces of piston
rings by gas-thermal spraying. The object of the study are processes of formation of the structure and properties of
coatings from powder materials. The presence in the deposited layer of a solid solution based on nickel, carbide phase,
borides of chromium and nickel, chromium silicides is established. The greatest macro- and microhardness is
possessed by fused layers containing the greatest number of strengthening phases. The conducted researches and
industrial tests allowed to introduce the coating into production.
INTRODUCTION
A significant place in the production of parts for
various purposes is taken by the manufacture of piston
rings of internal combustion engines, the main reason for
the decommissioning of which is wear and tear of
working surfaces. Therefore, much attention is paid to the
problems of wear resistance increase of the friction pairs
of the piston ring-sleeve and actual piston rings.
Creating a combination of high hardness and high
ductility in one material is possible only in heterogeneous
metal.
As of this date, there are virtually no reliable criteria
for optimizing the composition and structure of coatings
obtained during high-energy operations, and predicting
their performance and durability under friction. Due to
the dependence of the strength and wear resistance of
coatings on numerous factors related to the properties of
the substrate and coating materials and the parameters of
the technology of their application, it has been necessary
to undertake a research study. Setting theoretical and
technological bases of formation of the forecasted
structures and properties of the parts under at high-energy
influence for the purpose of increase of their durability is
an important and most pressing problem. Solving this
problem provides great opportunities in predicting and
managing the functional characteristics of piston rings in
a wide range of operating conditions.
PROBLEM OVERVIEW
High reliability and engine life largely depends on the
parts of the cylinder-piston group. This is because forcing
the internal combustion engine leads to a significant
increase in specific loads and temperature of the parts of
the cylinder-piston group, which causes cracking and
destruction of parts. As the specified details operate in
the conditions of intensive friction and wear, it is
necessary to provide high wear resistance of a surface [1].
Piston ring breakage is observed in almost all types of
engines. Electrolytic chromium coatings, which are
widely used in the practice of domestic and foreign
mechanical engineering, sometimes comply with
requirements of piston rings quite well. But a porous
layer of chromium with a thickness of 40…50 μm is
triggered within a few hours of operation, and then the
solid base begins to wear [1–4]. Electrolytic chromium
works poor on friction and wear at high temperatures,
which leads to softening.
Covering compound systems have a set of properties
that comply with the operating conditions of forced
diesels. But the process of applying such coatings is very
time consuming and efficient only in special cases [3–5].
In modern practice, instead of traditional methods of
chemo-thermal reprocessing to strengthen the surface,
high-temperature treatment methods are widely used, in
particular gas-plasma spraying. The process is
characterized by high productivity, simplicity, the
possibility of automation while ensuring sufficient
surface quality [1–3, 6].
For gas-plasma and other types of spraying the most
effective use of powders PG-SR3, PG-SR4 on the basis
of nickel with the addition of chromium, silicon, boron
and others. (Ni-Cr-Si-B system alloys) [1, 3]. They
provide high hardness and wear resistance of the surface.
There are no specific data in the literature on the structure
of the studied powders when they interact with the cast
mailto:diana@khadi.kharkov.ua
126 ISSN 1562-6016. ВАНТ. 2022. №4(140)
iron base. It is noted only [3–5] that the high hardness and
wear resistance due to the presence of carbides, borides,
carboborides.
The purpose of this work is to study powder materials
applied to the working surfaces of piston rings by gas-
thermal spraying.
The object of the study is processes of formation of
the structure and properties of coatings from powder
materials.
OBJECTIVES OF THE STUDY
1. To analyze the change in the structure and
properties of coatings of PG-SR powders (Ni-Cr-Si-B
alloy systems).
2. To determine the feasibility of heat treatment for
coatings of test powders.
3. To determine the effect of coatings of PG-SR
powders on the wear resistance of parts operating in
abrasive wear and corrosion.
MATERIAL AND METHODS
OF THE STUDY
Nickel-based powder materials are taken as materials
for strengthening piston rings, which can provide the
necessary properties for the operating conditions of the
selected parts and comply with the requirements for
sprayed materials (Table 1).
Coatings made of self-flux alloys such as PNHSR are
recommended based on literature [5–7] to create
resistance to abrasive and erosion wear in conditions of
corrosion and cavitation.
Therefore, powder materials from PN73H16S3R3,
PN70H17S4R4 alloys were taken as a basis in finding
ways to increase the resistance to abrasive wear in
corrosion of parts made of gray cast iron (Table 2).
Table 1
Chemical composition of powder materials
Powder
manufacturer
Chemical composition, %
Cr Si B Fe C Ni
PG-SR4
type
PN70H17S4R4
16.0…18.0 3.8…4.5 2.9…4.0 5.0 0.8…1.2 basis
PG-SR3
type
PN73H16S3R3
15.0…17.0 2.7…3.7 2.2…3.0 5.0 0.6…0.9 -"-
Table 2
Chemical composition of gray iron
Gray iron
SCh 25
Content of elements, %
C Si Mn Cr Ni P
3.2…3.4 1.4…1.7 0.6…0.9 – – up to 0.3
The coating process includes the following
operations: preliminary preparation of the surface of the
product for coating, the actual coating process, further
processing if necessary (fusing, heat treatment, etc.)
[8–11]. The performance properties of coatings are
formed in all operations of their production, so we
studied the impact of these operations on the structure
and properties of the coating.
Shot blasting was used to clean the sprayed surface
and bring it out of the state of thermodynamic
equilibrium with the medium. We used a fraction of
0.5…1.5 mm (GOST 11964-66) as an abrasive material.
Blowing was carried out at a compressed air pressure of
at least 0.4 MPa. The area of shot blasting is not less than
3 mm larger than the spray area. Another way to activate
the sprayed surface during plasma spraying is to heat it
to 50…130 °C depending on the material of the part.
Preheating was performed directly with a plasma torch
(Table 3).
Table 3
Preheating modes
Plasma gas
Plasmatron
current, A
Arc voltage,
V
Heating
distance, mm
Consumption of
plasma gas, l/min
Plasmatron
movement speed,
mm/min
Argon + nitrogen
(23…35%)
325…350 50…55 130…150 35…40 400…600
Plasma spraying modes shown in Table 4 were
carried out at the following constant parameters:
– speed of rotation of the samples – 45 rpm, linear
speed of movement of the samples relative to the plasma
jet – 18.4 m/min;
– the diameter of the charge line in the nozzle of the
anode – 2 mm;
– distance from the place of introduction of powder
to a cut of a nozzle – 4 mm;
– the axis of the plasma jet is perpendicular to the axis
of rotation of the sample.
The fusing of the layer was carried out under
conditions of accelerated gas-plasma surface heating
with relatively slow cooling (Fig. 1 and Table 4). In such
ISSN 1562-6016. ВАНТ. 2022. №4(140) 127
conditions, some approximation of the structure to
equilibrium is expected. In the initial powder and
especially in the layer after spraying the structures are
formed in nonequilibrium conditions [12, 13].
a b
Fig. 1. Scheme of coating of powder materials by gas-plasma method:
a – supply of powder and gas; b – own spraying [7]
Table 4
Modes of plasma spraying
Sprayed
material
Fractions,
μm
Spray mode settings
Plasma-
tron
current,
A
Arc
voltage,
V
Spray
distance,
mm
Plasma-
forming gas
mixture
Consumption of
plasma-forming
gas, l/min
Consumption
of trans-
porting gas,
l/min
Powder
consum
ption,
kg/h
PRHSR 45…100 280…300 40…45 100…120 5…10 35…40 6.0…9.0 2.5…3.3
The structure of the powder shows crystals, as well as a dispersed mixture of phases between them (Fig. 2).
а b
Fig. 2. Structure of powders for spraying PG-SR4 coatings
When X-raying, a multiphase structure is registered
in the source powder. The most fully represented lines of
solid solution are based on nickel and carbide phase of
Cr23С6type (Fig. 3,a). But many lines cannot be
unambiguously identified. We can find a match with the
main lines of chromium and nickel borides, chromium
silicides. The radiograph of the molten layer (see
Fig. 3,b) is quite identical to the radiograph of the
powder. The radiograph of the unfused layer (see Fig.
3,c) preserves the lines of chromium carbides and the
strongest lines of other phases. Preservation of the phase
lines in the spray layer without fusing and the layer after
quenching indicates that these phases are formed during
the primary crystallization. This is confirmed by the
metallography of the source powder and the source layer.
A similar structure is in the molten layer (Fig. 4): the
components are uniformly distributed in its volume.
Electron microscopic studies show that in the area of
coarse mixtures there are oriented areas, in the area of
small mixtures – non-oriented, less dispersed. It can be
assumed that the phase registered as rounded particles is
chromium carbide. Particles are stored when heating the
layer under hardening (see Fig. 4,d). Microhardness
measurements confirm this.
The multiphase layer revealed by X-raying is
confirmed by microscopic studies.
A similar phase and structural composition has a
coating of PG-SR3, a distinctive feature of the layer is a
smaller amount of coarse mixture of phases, which is
associated with changes in the content of the carbon
alloy.
128 ISSN 1562-6016. ВАНТ. 2022. №4(140)
Fig. 3. X-rays of PG-SR4 alloys:
a – PG-SR4 powder, λCr;
b – unfused layer; c – fuse layer
Fig. 4. Structure of the fuse layer PG-SR4:
a, b – coarse and fine mixtures; c – structure after
etching; d – structure after volumetric hardening
Fusing of the layers leads to partial fusing of the base
metal and activation of diffusion processes in the border
zone heated to high temperatures. This causes the base
material to mix with the layer material and form a new
alloy different in structure from the base and layer.
When sprayed with PG-SR metals in the structure of
the base metal in the border areas there are no changes,
because the total heating of the base metal is
insignificant, its interaction with the coating particles is
very weak (Fig. 5).
In the case of fusing of the obtained coatings, we
observe significant changes in the structure of cast iron at
the boundary with the layer and the layer at the boundary
with cast iron due to the intensification of diffusion
processes. At the boundary of the layer there is an
increase in the amount of coarse mixture of phases (see
Fig. 5), which can be explained by the diffusion of carbon
and iron from cast iron in the PG-SR4 and PG-SR3 layer.
A thin layer of single-phase alloy is formed at the
boundary with the molten metal. In the cast iron, a layer
with increased ferrite content is formed at the boundary,
which may be the result of diffusion into the nickel base,
which promotes graphitization.
Fig. 5. The structure of the boundary of the substrate
(gray cast iron) and the layer with unfused
coating PG-SR4
The structure of the PG-SR4 molten coating layer is
shown in Fig. 6.
a b
Fig. 6. The structure of the PG-SR4 molten coating layer: a – coarse mixtures; b – thin mixtures
a b
c d
a
c
b
ISSN 1562-6016. ВАНТ. 2022. №4(140) 129
These structural features of coatings from PG-SR
alloys and changes in the structure during further
treatments are reflected in changes in macro- and
microhardness (Fig. 7).
a
b
Fig. 7. Histogram of the influence of the PG-SR4 molten
coating layer on a – macro- and b – microhardness
indicators
In the studied parts of the cylinder-piston group of
internal combustion engines the fuse layers with the
greatest macro- and microhardness, are characterized by
the most complete set of strengthening phases. The
smallest microhardness in the layer after the volume
hardening as a result of dissolving at heating under the
hardening of a significant number of strengthening
phases and noticeable coagulation of the phases
preserved. High average microhardness of the unfused
layer, obviously, is connected with the specificity of
super-speed crystallization of particles at a peak, which
leads to the formation of a small grain of particles. The
strengthening effect of fine grains probably compensates
for the decrease in microhardness due to changes in phase
composition, which is observed when X-raying.
Evidence can be determined by comparing the
microhardness of the source powder and the particles of
the layer. The microhardness of the source powder is
characterized by a wide range of values:
5.700...8.900 MPa, which is associated with both the
structural composition of the particles and the possible
differences in composition. Particles with a smaller
number of detected strengthening phases (see Fig. 1,a)
have a lower hardness (5.700...8.250 MPa), and particles
with a structure shown in Fig.1,b have a higher hardness
(see Fig. 1,a).
In the sprayed unfused layer of piston ring parts, non-
fusing particles practically retain their hardness
(5.700…8.250 MPa), molten particles are characterized
by a smaller difference in microhardness values and an
even higher average level, approximately
7.300…8.500 MPa. Reduced macrohardness of the
unfused layer is due to its high porosity. The lower
hardness of the molten coating of PG-SRZ
(HV = 700...760), compared with PG-SR4
(HV = 760...820) is also associated mainly with a
decrease in the number of reinforcing phases.
Thus, the analysis of changes in the structure and
properties of coatings of PG-SR powders after spraying
and fusing showed that the best properties should have
fuse coatings.
Subsequent heat treatment associated with prolonged
high-temperature heating is undesirable, as it degrades
the structure and properties of the coating. It is advisable
to apply the coating on the part after finishing.
The possibility of using PG-SR4 coating to increase
the wear resistance of cast iron was tested in industrial
conditions. After grinding, the depth of the layer was
1.200 μm, the surface roughness Ra was not more than
2.5 μm.
In the studied operating conditions, the piston rings
fail after a month of operation due to intensive and very
uneven wear of the outer surface. The sprayed rings were
removed for inspection after three months of operation.
The surface of the sleeve after operation took the form of
a polished product (Ra not more than 0.32 µm) without
any local surface violations.
The conducted studies allow concluding that the
coating of products with PG-SR powders (alloys of the
Ni-Cr-Si-B system) is a reliable method of increasing the
wear resistance of parts operating in abrasive wear
conditions together with corrosion. Piston rings with
developed coatings were installed on the paired blocks of
the cylinder-piston group of the 10-cylinder locomotive
engine for operational tests. Serial chrome-plated rings
were installed on the odd-numbered units. After
100.000 km (corresponding to 4.000 h of operation), sets
of 4 rings from units 4, 8, and 7 were removed from the
locomotive for complex research. Analysis of the data
shows that the rings with the developed coating wear less
and wear the sleeve less than the serial rings with hard
and porous chrome coating.
CONCLUSIONS
1. Analysis of changes in the structure and properties
of coatings of PG-SR powders showed that the best
properties should have fuse coatings.
2. For coatings of PG-SR powders, heat treatment is
undesirable because it degrades the structure and
properties of the coating.
3. Coating of products with PG-SR powders (alloys
of the Ni-Cr-Si-B system) is a reliable method of
increasing the wear resistance of parts operating in
130 ISSN 1562-6016. ВАНТ. 2022. №4(140)
abrasive wear together with the corrosive effects of the
environment.
4. The obtained results were introduced at the
Malyshev Factory for parts of the cylinder-piston group.
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Article received 28.06.2022
СТРУКТУРА І ВЛАСТИВОСТІ ПОРОШКОВИХ ГАЗОПЛАЗМОВИХ ПОКРИТТІВ
НА ОСНОВІ НІКЕЛЮ
Д.Б. Глушкова, В.А. Багров, С.В. Демченко, В.М. Волчук, О.В. Калінін, Н.Є. Калініна
Розвиток сучасної техніки потребує постійного підвищення надійності та довговічності виробів. Широко
застосовувані в практиці вітчизняного та зарубіжного машинобудування покриття з електролітичного хрому
за кілька сотень годин спрацьовуються, вони незадовільно працюють на тертя та зношування за високих
температур. Предметом дослідження були порошкові матеріали на основі нікелю ПГ-СР3 та ПГ-СР4. Робота
присвячена дослідженню формування газоплазмових покриттів на деталях циліндропоршневої групи
двигунів внутрішнього згоряння з використанням самофлюсованих порошків на основі нікелю, а також зміні
структури та властивостей після напилення покриття, його оплавлення, наступного загартування. Мета
роботи – дослідження порошкових матеріалів, які нанесені на робочі поверхні поршневих кілець
газотермічним напиленням. Об'єктом дослідження є процеси формування структури та властивостей
покриттів із порошкових матеріалів. Встановлено наявність у напиленому шарі твердого розчину на основі
нікелю, карбідної фази, боридів хрому та нікелю, силіцидів хрому. Найбільшу макро- і мікротвердість мають
оплавлені шари, що містять найбільшу кількість зміцнювальних фаз. Проведені дослідження та промислові
випробування дозволили впровадити покриття у виробництво.
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