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Tribological and Microstructural Properties of Carbon Steel Coatings Fabricated by Wire Arc Spray

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Abstract

Thermal spray is a widely used process employed for the reduction of engine weight by replacing heavy cast iron liners inserted in cylinder bores. In particular, twin wire arc spray (TWAS) is one of the most popular thermal spray processes due to its reasonable cost and high deposition rate. In this study, ferrous coatings were fabricated by using TWAS with two variables: gas type and initial carbon content in wire. The investigation was focused on the relationship between variables and their effects on the oxidation, microstructure, and tribological properties. Especially, for evaluation of the tribological properties, a reciprocating sliding wear test was designed by considering realistic engine conditions. Individual splats forming the coating layer undergo oxidation which results in oxide formation, loss of alloying elements, and heat generation during spraying. From the results of experiments, it was figured out that the oxidation state is controlled by gas type, and its effects on microstructure and coating properties vary depending on the initial carbon content of the wire. Finally, it was confirmed that the wear resistance of the ferrous coating containing FeO and more carbon was better than the other for its improved frictional property and high hardness.

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Acknowledgements

This work was supported by the Hyundai Motor Group. The authors would like to thank the Hyundai Motor Group for financial support of this research.

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Authors and Affiliations

  1. Coke Making Department, POSCO, Pohang, 37859, Republic of Korea

    Jaewon Lee

  2. Division of Materials Science and Engineering, Hanyang University, Seoul, 04763, Republic of Korea

    Hansol Kwon & Changhee Lee

  3. Automotive Research and Development Division, Hyundai Motor Group, Hwaseong, 18280, Republic of Korea

    Young-Gi Kim

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  1. Jaewon Lee
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  2. Hansol Kwon
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  4. Changhee Lee
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Correspondence to Changhee Lee.

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Lee, J., Kwon, H., Kim, YG. et al. Tribological and Microstructural Properties of Carbon Steel Coatings Fabricated by Wire Arc Spray. Met. Mater. Int. 26, 650–659 (2020). https://doi.org/10.1007/s12540-019-00354-8

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