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Detonation Spraying of a Cermet Coating to Improve the Surface Properties of Tool Steel Parts Produced by the Selective Laser Melting Process

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Abstract

In this study, a novel attempt was made to deposit 86WC-10Co-4Cr cermet layer on 1.2709 tool steel substrate prepared by selective laser melting (SLM) process using detonation spraying method. The laser power of 350 W, scan speed of 25 mm/s, hatch spacing of 0.15 mm, and layer thickness of 50 µm were used to fabricate samples at 45° build orientation. The calculated volumetric energy density for fabricating the samples was 1867 J/mm3. The SLM printed samples were annealed and air cooled at 500 °C in a box furnace with a dwell time of 6 h. The average particle size of the powder measured before and after the ball milling process was 237.49 and 43.06 μm, respectively. A coating thickness of 100 μm was targeted using the detonation spraying process. An average spray loss of 13% was observed during cermet coating. The results were compared between the as-built specimen, the heat treated specimen and the 86WC-10Co-4Cr coated specimen. The average Vickers microhardness of the coated sample was found to be 81.04 and 48.96% superior to the as-built and heat treated samples. The average contact angles measured from the as-built, heat treated and coated samples were 82.5°, 64° and 93.9°, respectively, indicating the superior hydrophobic surface in the coated sample. The coated sample offered reduced abrasive wear, improved corrosion inhibition, and better 2D and 3D surface roughness properties than the as-built and heat treated samples, which promises its further use in cermet-based rapid tooling applications.

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Abbreviations

SLM:

Selective laser melting

WC:

Tungsten carbide

Co:

Cobalt

Cr:

Chromium

VED:

Volumetric energy density

HVOF:

High velocity oxygen fuel

CAD:

Computer aided design

STL:

Standard triangulation language

SEM:

Scanning electron microscope

XRD:

X-ray diffraction

WCA:

Water contact angle

FWHM:

Full width-half maximum

EDS:

Energy-dispersive x-ray spectroscopy

ASTM:

American Society for Testing and Materials

ISO:

International Organization for Standardization

Rp:

Maximum peak height of the roughness profile.

Rv:

Maximum valley depth of the roughness profile.

Rz:

Maximum height of roughness profile.

Rc:

Mean height of the roughness profile elements.

Rt:

Total height of roughness profile.

Ra:

Arithmetic mean deviation of the roughness profile.

Rq:

Root-mean-square (RMS) deviation of the roughness profile.

Rsk:

Skewness of the roughness profile.

Sq:

Root mean square height

Ssk:

Skewness

Sku:

Kurtosis

Sp:

Maximum peak height

Sv:

Maximum pit height

Sz:

Maximum height

Sa:

Arithmetic mean height

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Author notes

  1. N. Sathishkumar

    Present address: Department of Mechanical Engineering, St. Joseph’s College of Engineering, Old Mahabalipuram Road, Chennai, Tamil Nadu, 600119, India

  2. G. Arumaikkannu

    Present address: Department of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai, Tamil Nadu, 600025, India

Authors and Affiliations

  1. Department of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai, Tamil Nadu, 600025, India

    N. Sathishkumar

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N.S: Conceptualization, Methodology, Investigation, Writing–Original Draft, Writing—Revised Draft. G.A: Resources, Validation, Formal analysis, Supervision, Project administration.

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Correspondence to N. Sathishkumar.

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Sathishkumar, N., Arumaikkannu, G. Detonation Spraying of a Cermet Coating to Improve the Surface Properties of Tool Steel Parts Produced by the Selective Laser Melting Process. J Therm Spray Tech 32, 2439–2459 (2023). https://doi.org/10.1007/s11666-023-01651-w

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