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Research Papers: Friction & Wear

Erosive Wear Study of HVOF Spray Cr3C2–NiCr Coated CA6NM Turbine Steel

[+] Author and Article Information
Deepak Kumar Goyal

Baba Banda Singh Bahadur Engineering College,
Fatehgarh Sahib,
Punjab 140407, India
e-mail: erdeepakgoyal81@gmail.com

Harpreet Singh

Indian Institute of Technology Ropar,
Rupnagar,
Punjab 140001, India
e-mail: harpreetsingh@iitrpr.ac.in

Harmesh Kumar

University Institute of
Engineering and Technology,
Panjab University,
Chandigarh 160014, India
e-mail: shaarut@yahoo.com

Varinder Sahni

Sant Longowal Institute of Engineering and Technology,
Longowal,
Sangrur, Punjab 148106, India
e-mail: vsahni_2002@yahoo.co.in

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received May 28, 2013; final manuscript received April 11, 2014; published online June 2, 2014. Assoc. Editor: Jordan Liu.

J. Tribol 136(4), 041602 (Jun 02, 2014) (11 pages) Paper No: TRIB-13-1110; doi: 10.1115/1.4027621 History: Received May 28, 2013; Revised April 11, 2014

Degradation of surfaces of hydroturbine components caused by impact of abrasive particles carried by flowing water is a serious issue. To counteract the same, surface modification of turbine materials by the application of protective coatings is gaining popularity these days. In this work, Cr3C2–NiCr coating was deposited on CA6NM turbine steel by the HVOF spray process and studied with regard to its performance under different slurry erosion conditions. The effect of three parameters, namely average particle size of slurry particles, speed (rpm), and slurry concentration on slurry erosion of this coating material, was studied by using a high speed erosion test rig. The analysis of the surfaces of the samples before and after slurry erosion tests was done by using SEM. The HVOF sprayed Cr3C2–NiCr coating showed very good performance under slurry erosion in comparison with uncoated CA6NM steel.

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Figures

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Fig. 1

SEM micrograph of Cr3C2–NiCr powder

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Fig. 2

Schematic diagram of high speed erosion test rig (TR401, Ducom, India) [15]

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Fig. 3

SEM micrograph of erodent particles used in the investigation, which were collected from Nathpa Jakhri Power Plant, Himachal Pradesh, India [15]

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Fig. 4

Particle size distribution of silt samples of 100 and 300 μm average particle size [15]

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Fig. 5

SEM analysis of HVOF-sprayed Cr3C2–NiCr on CA6NM steel: (a) cross-sectional micrograph and (b) surface micrograph

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Fig. 6

Cumulative erosion curves for uncoated and HVOF spray Cr3C2–NiCr coated CA6NM steel specimens at (a) 2250 rpm using slurry of 10,000 ppm concentration of 100 μm average particle size, (b) 2250 rpm using slurry of 30,000 ppm concentration of 300 μm average particle size, (c) 4500 rpm using slurry of 10,000 ppm concentration of 300 μm average particle size, and (d) 4500 rpm using slurry of 30,000 ppm concentration of 100 μm average particle size

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Fig. 7

Effect of impact velocity of impacting particles/rotational speed of rotor on erosion rate of uncoated and HVOF spray Cr3C2–NiCr coated CA6NM steels

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Fig. 8

Effect of particle size on erosion rate of uncoated and HVOF spray Cr3C2–NiCr coated CA6NM steel

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Fig. 9

Effect of slurry concentration on erosion rate of uncoated and HVOF spray Cr3C2–NiCr coated CA6NM steel

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Fig. 10

Slurry erosion behavior of uncoated CA6NM steel under the interactive effects of (a) velocity and average particle size, (b) velocity and slurry concentration, and (c) slurry concentration and average particle size

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Fig. 11

Slurry erosion behavior of HVOF spray Cr3C2–NiCr coated CA6NM steel under the interactive effects of (a) velocity and average particle size, (b) velocity and slurry concentration, and (c) slurry concentration and average particle size

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Fig. 12

Signal to noise (S/N) ratio graph for slurry erosive wear of (a) uncoated CA6NM steel and (b) HVOF spray Cr3C2–NiCr coated CA6NM steel

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Fig. 13

Variation of impact angle of particle over the target surface

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Fig. 14

SEM micrograph of eroded surface of the uncoated CA6NM steels under (a) 2250 rpm using slurry of 10,000 ppm concentration of 100 μm average particle size, (b) 2250 rpm using slurry of 30,000 ppm concentration of 300 μm average particle size, (c) 4500 rpm using slurry of 10,000 ppm concentration of 300 μm average particle size, and (d) 4500 rpm using slurry of 30,000 ppm concentration of 100 μm average particle size

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Fig. 15

SEM of eroded surface of HVOF sprayed Cr3C2–NiCr coating on CA6NM steel under (a) 2250 rpm using slurry of 10,000 ppm concentration of 100 μm average particle size, (b) 2250 rpm using slurry of 30,000 ppm concentration of 300 μm average particle size, (c) 4500 rpm using slurry of 10,000 ppm concentration of 300 μm average particle size, and (d) 4500 rpm using slurry of 30,000 ppm concentration of 100 μm average particle size

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