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Frontiers of Mechanical Engineering

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ISSN 2095-0241(Online)

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Front Mech Eng    2011, Vol. 6 Issue (1) : 118-135    https://doi.org/10.1007/s11465-011-0127-0
RESEARCH ARTICLE
Durability of plasma-sprayed Cr3C2-NiCr coatings under rolling contact conditions
Xiancheng ZHANG1,2(), Fuzhen XUAN1, Shantung TU1, Binshi XU2, Yixiong WU2
1. Key Laboratory of Safety Science of Pressurized System, Ministry of Education, East China University of Science and Technology, Shanghai 200237, China; 2. Shanghai Key Lab of Materials Laser Processing and Modification, Shanghai Jiao Tong University, Shanghai 200030, China
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Abstract

The aim of this paper was to address the rolling contact fatigue (RCF) failure mechanisms of plasma-sprayed Cr3C2-NiCr coatings under different tribological conditions of contact stress. Weibull distribution plots of fatigue lives of the coated specimens at different contact stresses were obtained. The failure modes of coatings were identified on the basis of wore surface observations of the failed coatings. Results showed that the RCF failure modes can be classified into four main categories, i.e., surface abrasion, spalling, cohesive delamination, and interfacial delamination. The probabilities of the surface abrasion and spalling type failures were relatively high at low contact stress. When the coatings were subjected to abrasion and spalling type failures, the failure of the coating was depended on the microstrcture of the coating. The stress concentration near the micro-defects in the coating may be the may reason for the formation of spall. The coatings were prone to fail in delamination under higher contact stresses. However, the delamination of coating may be related to distribution of shear stress amplitude within coating. The location of maximum shear stress amplitude can be used as a key parameter to predict the initiation of subsurface cracks within coating in rolling contact.
Keywords rolling contact fatigue      coating      Weibull distribution      failure mode      mechanism     
Corresponding Author(s): ZHANG Xiancheng,Email:xczhang@ecust.edu.cn   
Issue Date: 05 March 2011
 Cite this article:   
Xiancheng ZHANG,Fuzhen XUAN,Shantung TU, et al. Durability of plasma-sprayed Cr3C2-NiCr coatings under rolling contact conditions[J]. Front Mech Eng, 2011, 6(1): 118-135.
 URL:  
https://academic.hep.com.cn/fme/EN/10.1007/s11465-011-0127-0
https://academic.hep.com.cn/fme/EN/Y2011/V6/I1/118
ProcessCoating materialsThickness/μmHardness/HVContact stress/MPaRCF lifeRef.
HVOFWC-12%Co,WC-17%Co, WC-10%Co-4%Cr100758–1208420, 510, 62010 million cycles[1]
WC-12%Co50–22512962700–37000.05–68.5 million cycles[7]
WC-20%Cr-7%Ni39–95703–9641000–14000.07–20 million cycles[8]
WC-Co50,1509402400–30001–328 min[9]
WC-12%Co20,150,25013181700–190018–7260 min[10]
WC-20%Cr-7%Ni50–113744–817600, 800,14000.025–20 million cycles[11]
APSWC-12%Co100888420, 510, 62010 million cycles[1]
WC-15%Co501200N/A10–350 min[4]
WC-15%Co60–26011582740, 31000.058–38.61 million cycles[12]
Cr3C2-25%NiCr50,100,210438–6221300,1500, 20340.01–8.775 million cycles[13]
WC-15%Co60–260N/A2740, 31006–4290 min[14]
Ni-Cr-B-Si-C200.45N/A15003–6 million cycles[15]
WC-15%Co, Al2O3701200580010–180 min[16]
Al2O3, TiO2, Mo, Cr2O3-SiO2-TiO2300–350491–1089822–1086<10 million cycles[17]
D-GunWC-15%Co501200N/A10–350 min[4]
Cr3C2-25%NiCr50,100,2108891300, 20340.094–3.642 million cycles[13]
WC-15%Co, Al2O3701200580010–180 min[16]
Tab.1  Published findings for RCF performance of thermally sprayed coatings
Argon gas flow rate60 L/min
Hydrogen gas flow rate3.33 L/min
Nitrogen gas flow rate10 L/min
Spraying voltage140 V
Spraying current360 A
Powder feed rate30 g/min
Tab.2  Parameters used for plasma spraying
Fig.1  Morphology of CrC-NiCr powder
Fig.2  1—temperature sensor; 2—spindle driving motor; 3—belt drive; 4—speed sensor; 5—follower pulley; 6—stand; 7—weight; 8—cup assembly; 9—vibration sensor; 10—loading lever; 11—gear as a collet; 12—coated specimen; 13—bearing with 11 balls
Schematic of the rolling contact test machine
Fig.3  Finite-element meshes used for shear stress distributions within coating and substrate
Fig.4  Weibull plots of rolling contact fatigue lives of coatings tested at different contact stresses
Contact stress (GPa)Modulus, β N10 (×106 cycles)N50 (×106 cycles)Na(×106 cycles)N90 (×106 cycles)Na 90% Confidence band (×106 cycles)Na 95% Confidence band (-106 cycles)
LowerHigherLowerHigher
1.5072.110.75761.84752.19733.26061.84022.62381.75002.7591
1.8981.670.44921.38411.72292.83551.37572.15771.29072.2998
2.3912.100.33670.92241.2221.75330.91871.37080.86811.4508
12.66
2.8821.980.15480.40820.49290.75710.40700.59690.38550.6301
6.48
Tab.3  Life parameters at different contact stresses and slops of Weibull plots
Fig.5  S-N curves for CrC-NiCr coatings
Fig.6  Cross-sectional microstructure of plasma sprayed CrC-NiCr coating
CodeRCF life (cycles)Failure modeCodeRCF life (cycles)Failure mode
A10.458×106ID1B10.372×106ID
A20.733×106DWC2B20.642×106DWC
A31.192×106DWCB30.733×106SP
A41.283×106DWCB40.789×106DWC
A51.375×106DWCB50.825×106SP
A61.467×106DWCB61.008×106ID
A71.925×106SA3B71.162×106SP
A82.108×106DWCB81.283×106SP
A92.292×106SP4B91.833×106SP
A102.383×106SAB102.118×106DWC
A112.750×106SPB112.292×106SP
A123.208×106DWCB123.232×106SP
A134.075×106SAB133.575×106SP
Tab.4  Detailed results from worn surface observations of failed coatings tested at contact stresses of 1.507 GPa (A1–A13) and 1.898 GPa (B1–B13)
Fig.7  Surface observations of failed coating A6 tested at contact stress of 1.507?GPa. (a) Overall view of wear track; (b) delamination in SEI; (c) delamination in BEI; (d) higher-magnification at edge
Fig.8  Surface observations of failed coating A7 tested at contact stress of 1.507 GPa. (a) Overall view of the wear track; (b) higher magnification
Fig.9  Spall on worn surface of failed coating with fatigue life of 2.292 × 10 cycles at contact stress of 1.898 GPa. (a) Overall view; (b) breakage of lamellar structures at bottom surface of spall
Fig.10  Overall view of spall on worn surface of failed coating with fatigue life of 3.232 × 10 cycles at contact stress of 1.898?GPa
Fig.11  Surface observations of failed coating B2 with fatigue life of 0.642 × 10at contact stress of 1.898 GPa. (a) Overview of wear track; (b) delamination area in BEI
Fig.12  Surface observations of failed coating B4 with fatigue life of 0.789 × 10at contact stress of 1.898 GPa, overview of delamination area. (a) SEI; (b) BEI
CodeRCF life (cycles)Failure modeCodeRCF life (cycles)Failure mode
C10.245×106IDD10.082×106ID
C20.276×106IDD20.092×106ID
C30.367×106IDD30.183×106ID
C40.463×106DWCD40.217×106ID
C50.668×106IDD50.367×106DWC
C60.733×106IDD60.382×106ID
C70.917×106SPD70.495×106SP
C81.192×106IDD80.513×106ID
C91.451×106DWCD90.550×106SP
C101.515×106SPD100.629×106SP
C111.623×106SPD110.660×106SP
C121.650×106SPD120.733×106SP
C131.833×106SPD130.798×106SP
Tab.5  Detailed results from worn surface observations of failed coatings tested at contact stresses of 2.391 GPa (C1–C13) and 2.882 GPa (D1–D13)
Fig.13  Interfacial delamination on surface of failed specimen with life of 0.917 × 10 cycles at =2.391 GPa. (a) Overall view of the delamination; (b) cliff edge
Fig.14  Delamination on surface of failed specimen with life of 0.458 × 10 cycles at =2.391 GPa. (a) SEI; (b) BEI
Fig.15  Worn surface observations of failed specimen with life of 1.283 × 10 cycles at =2.391 GPa. (a) Overall view; (b) decohesion of splats
Fig.16  Worn surface observation of failed coating with fatigue life of 0.217 × 10 cycles at = 2.882 GPa. (a) Overall view; (b) cliff edge
Fig.17  Worn surface observation of failed coating with fatigue life of 0.367 × 10 cycles at =2.882 GPa. (a) Overall view; (b) delamination area
Fig.18  Distributions. (a) Orthogonal shear stress; (b) maximum shear stress; (c) shear stress amplitude, within coating and substrate with respect to different contact stresses
Fig.19  Number of coatings failed in individual modes at individual contact stresses
Fig.20  Schematically showing formation of spall at coating surface
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