Skip to main content
SpringerLink
Log in

Post-processing parameter optimization to enhance the surface finish of HVOF-developed coatings

  • Original Paper
  • Published:
Multiscale and Multidisciplinary Modeling, Experiments and Design Aims and scope Submit manuscript

Abstract

Composite coatings of titanium carbide (TiC) and chromium oxide (Cr2O3) were successfully developed on the surface of Al-6061 aluminium alloy plates using high-velocity oxy-fuel (HVOF) thermal spray technique. The surface quality tested using the surface roughness tester (SRT) showed a high surface roughness in both TiC + 10% Cr2O3 and Cr2O3 + 10%TiC coatings. The high surface roughness obtained in the coated surfaces posed a limitation in its use as both tribological and corrosion protection coatings. Post-processing of the coated surfaces was performed through hot and cold compression techniques, respectively, to reduce the surface roughness. The influencing post-processing parameters such as the thermal load, compressive load and loading time durations were optimized using the Taguchi analysis in combination with Single-Response Performance Index (SPI), to minimize the surface roughness and enhance the surface finish of the coated component. The obtained optimized levels were utilized in the post-processing of the coated samples to obtain the lowest surface roughness value. The post-processed surface roughness (Ra) was validated using the surface roughness tester. The optimization technique using Taguchi design of experiments showed that the measured and the regression equation computed values were highly similar with minimalistic deviations. The post-processing of the coated surface showed an improved surface finish by reducing the measured Ra from 19.383 µm to lowest of 3.345 µm after post-processing. The research concluded that hot compression technique provided better surface finish as compared to the cold compression technique.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  • Aslan B (2020) Optimization, and analysis of process parameters for flank wear, cutting forces and vibration in turning of AISI 5140: a comprehensive study. Measurement 163:107959

    Article  Google Scholar 

  • Balu MS, Vigneshkumar M, Ashokavarthanan P, Vijay Prakash G, Sekar P (2021) Multi-objective optimization of process parameters in dry sliding wear characteristics of Al/sic composites using Taguchi grey relation analysis. Mater Today Proc. https://doi.org/10.1016/j.matpr.2020.09.133

    Article  Google Scholar 

  • Behera A (2020) Optimization of process parameters in laser welding of dis-similar materials. Mater Today Proc. https://doi.org/10.1016/j.matpr.2020.07.148

    Article  Google Scholar 

  • Chen D-D, Lin YC, Wu F (2019) A design framework for optimizing forming processing parameters based on matrix cellular automaton and neural network-based model predictive control methods. Appl Math Model 76:918–937

    Article  MathSciNet  Google Scholar 

  • Goyal K et al (2018) Mechanical and microstructural properties of carbon nanotubes reinforced chromium oxide coated boiler steel. World J Eng. https://doi.org/10.1108/WJE-10-2017-0315

    Article  Google Scholar 

  • Guney B, Mutlu I (2019) Wear and corrosion resistance of Cr2O3%–40%TiO2 coating on gray cast-iron by plasma spray technique. Mater Res Express. https://doi.org/10.1088/2053-1591/ab2fb7

    Article  Google Scholar 

  • Khameneh Asl S, Rabizadeh T, Noori NF (2019) The effects of heat treatment on the corrosion behavior of HVOF-sprayed WC-17 wt% Co coatings. Prot Met Phys Chem Surf 55(5):936–941

    Article  Google Scholar 

  • Li H, Li J, Yan C, Zhang X, Xiong D (2020) Microstructure and tribological properties of plasma-sprayed Al0.2Co1.5CrFeNi15T–-Ag composite coating from 25 to 750 °C. J Mater Eng Perform 29:1640–1649

    Article  Google Scholar 

  • Luo J, Sun Y (2020) Optimization of process parameters for the minimization of surface residual stress in turning pure iron material using central composite design. Measurement 163:108001

    Article  Google Scholar 

  • Nagabhushana N, Rajanna S, Mathapati M, Ramesh MR, Koppad PG, Reddy NC (2019) Microstructure and tribological characteristics of APS sprayed NiCrBSi/flyash cenosphere/Cr2O3 and NiCrBSi/flyash cenosphere/Mo composite coatings at elevated temperatures. Mater Res Express. https://doi.org/10.1088/2053-1591/ab24f1

    Article  Google Scholar 

  • Nagendra J, Ganesha Prasad MS (2019) FDM process parameter optimization by Taguchi technique for augmenting the mechanical properties of nylon-aramid composite used as filament material. J Inst Eng India Ser C. https://doi.org/10.1007/s40032-019-00538-6

    Article  Google Scholar 

  • Nagendra J, Ganesha Prasad MS, Shashank S, Ali SM (2018) Comparison of tribological behavior of nylon aramid polymer composite fabricated by fused deposition modeling and injection molding process. Int J Mech Eng Technol 9(13):720–728

    Google Scholar 

  • Nagendra J, Srinath MK, Sujeeth S, Naresh KS, Ganesha-Prasad MS (2021) Optimization of process parameters and evaluation of surface roughness for 3D printed nylon-aramid composite. Mater Today Proc. https://doi.org/10.1016/j.matpr.2020.10.609

    Article  Google Scholar 

  • Nath P, Olson JD, Mahadevan S, Lee Y-TT (2020) Optimization of fused filament fabrication process parameters under uncertainty to maximize part geometry accuracy. Addit Manuf 35:101331

    Google Scholar 

  • Prabhu PR, Kulkarni SM, Sharma S (2020) Multi-response optimization of the turn-assisted deep cold rolling process parameters for enhanced surface characteristics and residual stress of AISI 4140 steel shafts. J Mater Res Technol 9(5):11402–11423

    Article  Google Scholar 

  • Pulsford J, Venturi F, Kamnis S, Hussain T (2020) Sliding wear behaviour of WC-Co reinforced NiCrFeSiB HVOAF thermal spray coatings against WC-Co and Al2O3 counterbodies. Surf Coat Technol 386:125468

    Article  Google Scholar 

  • Reddy NC, AjayKumar BS, Reddappa HN, Ramesh MR, Koppad PG, Kord S (2018) HVOF sprayed Ni3Ti and Ni3Ti+(Cr3C2+20NiCr) coatings: microstructure, microhardness and oxidation behavior. J Alloys Compd. https://doi.org/10.1016/j.jallcom.2017.11.131

    Article  Google Scholar 

  • Saladi S et al (2018) Evaluation of microstructural features of HVOF sprayed Ni–20Al coatings. Trans Indian Inst Met 71(10):2387–2394

    Article  Google Scholar 

  • Shivalingaiah K, Sridhar KS, Sethuram D, Shivananda Murthy KV, Koppad PG, Ramesh CS (2019) HVOF sprayed Inconel 718/cubic boron nitride composite coatings: microstructure, microhardness and slurry erosive behavior. Mater Res Express. https://doi.org/10.1088/2053-1591/ab7067

    Article  Google Scholar 

  • Srinath MK, Ganesha Prasad MS (2017a) Surface morphology and hardness analysis of TiCN coated AA7075 aluminium alloy. J Inst Eng India Ser C. https://doi.org/10.1007/s40032-017-0427-1

    Article  Google Scholar 

  • Srinath MK, Ganesha Prasad MS (2017b) Corrosion analysis of TiCN coated Al-7075 alloy for marine applications: a case study. J Inst Eng India Ser C. https://doi.org/10.1007/s40032-018-0469-z

    Article  Google Scholar 

  • Srinath MK, Ganesha Prasad MS (2020) Wear and corrosion resistance of titanium carbo-nitride coated Al-7075 produced through PVD. Bull Mater Sci 43:108

    Article  Google Scholar 

  • Srinath MK, Nagendra J, Puneeth HV et al (2021) Micro-structural, physical and tribological properties of HVOF spayed (TiC + Cr2O3) composite coatings. Mater Today Proc. https://doi.org/10.1016/j.matpr.2020.10.342

    Article  Google Scholar 

  • Suresh A, Diwakar G (2021) Optimization of process parameters in plasma arc cutting for TWIP steel plates. Mater Today Proc. https://doi.org/10.1016/j.matpr.2020.07.383

    Article  Google Scholar 

  • Wang L, Zhang L, Huang Q, Zhang C, Zhang L (2020) Characteristics and thermal shock resistance of HVOF-sprayed TiAlNb coatings. J Therm Spray Technol. https://doi.org/10.1007/s11666-020-01061-2

    Article  Google Scholar 

  • Yao H-L, Xiao-Zhen Hu, Wang H-T, Chen Q-Y, Bai X-B, Zhang M-X, Ji GangChang (2019) Microstructure and corrosion behavior of thermal-sprayed hydroxyapatite/magnesium composite coating on the surface of AZ91D magnesium alloy. J Therm Spray Technol 28:495–503

    Article  Google Scholar 

Download references

Funding

The authors declare that there are no sources of external funding.

Author information

Authors and Affiliations

  1. Mechanical Engineering Department, New Horizon College of Engineering, Bangalore, Karnataka, 560103, India

    M. K. Srinath & J. Nagendra

Authors
  1. M. K. Srinath
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. Nagendra
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. K. Srinath.

Ethics declarations

Conflict of interest

The authors declare that there are no conflicting interests with any single person or party.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Srinath, M.K., Nagendra, J. Post-processing parameter optimization to enhance the surface finish of HVOF-developed coatings. Multiscale and Multidiscip. Model. Exp. and Des. 5, 255–267 (2022). https://doi.org/10.1007/s41939-022-00116-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s41939-022-00116-x

Keywords

Search

Navigation