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Analyzing the mechanisms of Al2O3-TiO2 coating for enhanced slurry erosion resistance on AISI410 stainless steel

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Abstract

In this research, the optimization of D-gun process parameters for depositing Al2O3-TiO2 coatings on SS410 steel has been explored, with a specific focus on enhancing resistance to slurry erosion. A hybrid intelligent approach based on an artificial neural network (ANN) is employed to quantitatively analyze the influence of jet velocity, impingement angle, and slurry concentration on erosion performance. The findings reveal the significant impact of these parameters, with higher jet velocities and slurry concentrations, coupled with lower impingement angles, leading to increased mass loss, underscoring the need for precise parameter optimization. The ANN model has been developed which is further optimized by the amended slime mold algorithm (ASMA) for accurate predictions for optimal parameter selection to enhance coating durability. Additionally, metallurgical and mechanical characterizations offer quantitative insights into material properties, including porosity percentage, microhardness, surface roughness, and bond strength, all of which play critical roles in erosion resistance. Through SEM imaging, erosion mechanisms such as lip and crater formation, plows, erosive grooves, and crowded pits are quantitatively identified, shedding light on erosive wear patterns. Comparative analysis of coated samples quantitatively underscores the varying levels of erosive damage and resistance, emphasizing the essential role of coating composition and process parameters.

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Authors and Affiliations

  1. Department of School of Life Long Learning, Galgotias University, Plot No. 2, Sector -17 A, Yamuna Expressway, Greater Noida, Uttar Pradesh, 203201, Gautam Budhh Nagar, India

    Praveen Kumar Saini

  2. Department of Mechanical Engineering, IIMT Group of Colleges, Knowledge Park III, plot no. 19 & 20-A, Greater Noida, Uttar Pradesh, 201306, India

    Praveen Kumar Saini

  3. Department of Mechanical Engineering, Sant Longowal Institute of Engineering and Technology, Longowal, Punjab, 148106, India

    Anuj Bansal, Vikrant Singh, Anil Kumar Singla & Harish Kumar Arya

  4. Faculty of Geoengineering, Mining and Geology, Wroclaw University of Science and Technology, Na Grobli 15, 50-421, Wroclaw, Poland

    Sumika Chauhan & Govind Vashishtha

  5. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758, Opole, Poland

    Munish Kumar Gupta

  6. Department of Mechanical Engineering, Graphic Era Deemed to Be University, Dehradun, India

    Munish Kumar Gupta

  7. Thermo Fisher Scientific India Pvt. Ltd., Sector 2, Noida, Uttar Pradesh, 201301, India

    Manish Kumar

Authors
  1. Praveen Kumar Saini
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  2. Anuj Bansal
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  3. Vikrant Singh
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  4. Sumika Chauhan
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  5. Govind Vashishtha
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  6. Anil Kumar Singla
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  7. Harish Kumar Arya
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  8. Munish Kumar Gupta
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  9. Manish Kumar
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Corresponding authors

Correspondence to Anuj Bansal or Govind Vashishtha.

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Saini, P.K., Bansal, A., Singh, V. et al. Analyzing the mechanisms of Al2O3-TiO2 coating for enhanced slurry erosion resistance on AISI410 stainless steel. Int J Adv Manuf Technol 130, 5837–5851 (2024). https://doi.org/10.1007/s00170-024-13077-x

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  • DOI: https://doi.org/10.1007/s00170-024-13077-x

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