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Effect of Residual Stress on the Wear Resistance of Thermal Spray Coatings

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Abstract

The wear resistance of thermal spray coatings mainly depends on coating properties such as the microstructure, hardness, and porosity, as well as on the residual stress in the coating. The residual stress is induced by a variety of influences e.g., temperature gradients, difference of the thermal expansion coefficient of the coating/substrate materials, and the geometry of the components. To investigate the residual stress, the impulse excitation technique was employed to measure the Young’s and shear moduli. The residual stress was determined by the hole-drilling method and x-ray diffraction. Pin-on-Disk and Pin-on-Tube tests were used to investigate the wear behavior. After the wear tests, the wear volume was measured by means of a 3D-profilometer. The results show that the value of the residual stress can be modified by varying the coating thickness and the substrate geometry. The compressive stress in the HVOF-sprayed WC-Co coatings has a significant positive influence on the wear resistance whereas the tensile stress has a negative effect.

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Acknowledgments

This research was conducted in close co-operation with the Institute of Machining Technology (ISF) and the Institute of Forming Technology and Lightweight Construction (IUL) at the TU Dortmund within the framework of the Collaborative Research Center (German: Sonderforschungsbereich), SFB 708, TP C2. The authors thank in particular S. Goeke (ISF, TU Dortmund) for the finishing of the coating on tubes and F. Steinbach (IUL, TU Dortmund) for the incremental hole-drilling measurement, as well as the German Research Foundation (German: Deutsche Forschungsgemeinschaft, DFG) for their financial support.

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  1. TU Dortmund - Institute of Materials Engineering, Leonhard-Euler-Str. 2, 44225, Dortmund, Germany

    W. Luo, U. Selvadurai & W. Tillmann

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  1. W. Luo
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Correspondence to W. Luo.

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Luo, W., Selvadurai, U. & Tillmann, W. Effect of Residual Stress on the Wear Resistance of Thermal Spray Coatings. J Therm Spray Tech 25, 321–330 (2016). https://doi.org/10.1007/s11666-015-0309-0

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  • DOI: https://doi.org/10.1007/s11666-015-0309-0

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