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Solution to Inverse Problem of Manufacturing by Surface Modification with Controllable Surface Integrity Correlated to Performance: A Case Study of Thermally Sprayed Coatings for Wear Performance

[+] Author and Article Information
X.P. Zhu

Surface Engineering Laboratory, School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
xpzhu@dlut.edu.cn

P.C. Du

Surface Engineering Laboratory, School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
lydpch@mail.dlut.edu.cn

Y. Meng

Surface Engineering Laboratory, School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
ymeng@mail.dlut.edu.cn

M.K. Lei

Surface Engineering Laboratory, School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
surfeng@dlut.edu.cn

D.M. Guo

Key Laboratory for Precision and Non-traditional Machining of the Ministry of Education, Dalian University of Technology, Dalian 116024, China
surfeng163@163.com

1Corresponding author.

ASME doi:10.1115/1.4036184 History: Received December 11, 2016; Revised February 14, 2017

Abstract

Inverse problem of manufacturing is studied under a framework of high performance manufacturing of components with functional surface layer where controllable generation of surface integrity is emphasized due to its pivotal role determining final performance. Surface modification techniques capable of controlling surface integrity are utilized to verify such a framework of manufacturing, by which the surface integrity desired for a high performance can be more effectively achieved as reducing the material and geometry constraints of manufacturing otherwise unobtainable during conventional machining processes. Here, thermal spraying of WC-Ni coatings is employed to coat stainless steel components for water-lubricated wear applications, on which a strategy of direct problem from process to performance can be implemented with surface integrity adjustable through spray angle and inert N2 shielding. Multiple surface integrity parameters are evaluated to identify the major ones responsible for wear performance by elucidating the wear mechanism, involving surface features (coating porosity and WC phase retention) and surface characteristics (microhardness, elastic modulus and toughness). The surface features predominantly determine tribological behaviors of coatings in combination with the surface characteristics that are intrinsically associated with the surface features. Consequently, the spray process could be designed with improved N2 shielding according to the desired surface integrity parameters for higher wear resistance. It is demonstrated a possibility of solving inverse problem of manufacturing if the correlations from processes to performance are fully understood and established, facilitated by effectively reducing the manufacture constraints toward a material and geometry integrated manufacturing.

Copyright (c) 2017 by ASME
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