Effect of Thermal Spray Parameters on Wear Resistance for Medium Carbon Steel


AbstractThis research was conducted following the process of coating by thermal spray flametechnology through the use of a mixture gas composed of oxygen and acetylene for thepurpose of obtaining a surface layer of ceramic coating on the surface of the mediumcarbon steel type (AISI 1050), provides an increase in the surface properties of themetal which is represented by wear resistance. The research carried out in threesuccessive stages, the first stage included the preparation of the surface of specimens aswell as the preparation of powder coating and analysis of chemical components of thespecimens and coating powders. While the second stage included the implementation ofthe connector coating process (nickel - aluminum) and coating the main (alumina) usinga flame spray coating process conducted in different ways for each specimen by changein spraying factors, which included the surface roughness of the base specimens, thetemperature of the surface of the base specimens before the coating process, the distancebetween the spray gun nozzle and the surface of the specimens and thickness of thecoating. The third stage included the testing of standard tests, which includes adhesiontest, check wear and roughness of different coatings in addition to a microscopicexamination of the successive layers of coat and surface basis.It has been reached on the best variables that give the high adhesion and the lowestwear rate, where the results showed that the increase of roughness from (0.85 μm) to(10.50 μm) led to the low rate of wear by up to about (51%) more than half, The besttemperature of the heated surface of the foundation before the coating process to obtainthe lowest rate of wear and higher adhesion ranging from (200 C º) to (300 C º). Whilethe optimal distance between the spray nozzle and the surface of the specimen rangingfrom (150 mm) to (200 mm) and thickness optimized for coating ranging from(0.15mm) to (0.5mm) for the best coating with the lowest wear rate.