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. 2020 Nov 25;13(23):5344.
doi: 10.3390/ma13235344.

Thermodynamics and Mechanics of Thermal Spraying of Steel EN 10060 Substrate with NiCrBSi Alloy after Milling

Jan Valíček  1 , Marta Harničárová  1 , Jan Řehoř  1 , Milena Kušnerová  1 , Ludmila Kučerová  1 , Miroslav Gombár  1 , Jaroslava Fulemová  1 , Jan Filipenský  2 , Jan Hnátík  1
Affiliations

Thermodynamics and Mechanics of Thermal Spraying of Steel EN 10060 Substrate with NiCrBSi Alloy after Milling

Jan Valíček et al. Materials (Basel). .

Abstract

The objective of this paper is to present a new way of identifying and predicting the relationship between thermodynamic and physical-mechanical parameters in the formation of a layer after spraying on a substrate with NiCrBSi alloy and its subsequent processing by milling. The milling of the spherical surface of the EN 10060 material after spraying was performed on the DMU 40 eVolinear linear milling centre. The experimental part of the article is focused on investigating the influence of cutting parameters when machining a selected combination of materials (substrate-coating: EN 10060 steel-NiCrBSi alloy). The experiment is based on the results of direct measurements of three basic cutting parameters, namely: cutting speed vc (m∙min-1), feed per tooth fz (mm), and the depth of cut ap (mm). The new distribution functions of selected cutting parameters were derived. The analytical results of the thermodynamic calculations performed on nickel-based alloy can be used for accurate predictions of the technological parameters of milling a spherical substrate made of EN 10060 steel after HVOF spraying, and also for both sample preparation and the subsequent production of high-quality coatings.

Keywords: HVOF; NiCrBSi alloy; coatings; mechanics; thermal spraying; thermodynamics.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
Linear milling centre DMU 40 eVolinear during milling of the examined sample. The sample is clamped by means of a mandrel in a universal chuck. The tool is clamped in a KFH (high power milling chuck).
Figure 2
Figure 2
EDX analysis of NiCrBSi coating (a) before; (b) after machining.
Figure 3
Figure 3
Graph of Rmp = function (ExpNO) values calculated according to Table 3 for RmpSUB substrate materials (blue), RmpXY interlayers (green), and RmpX overlay spraying layers (red); it can be observed that at the level of ExpNO = 6, the curves of all three materials converge to the value Rmp > 0.
Figure 4
Figure 4
Dependence of stress σrzq on the depth of cut ap.
Figure 5
Figure 5
Detail of the course of entropy distribution Sdt-ap. Depth of engagement ap, or neutral engagement apo under a fixed tool are in the function of deformation lengths (ap, ap0) = fce(h, h0).
Figure 6
Figure 6
Distribution curves for substrate, for XY-layer transition material, and for spraying material (Sdt) = (h).
Figure 7
Figure 7
Distribution curves of stress-strain and thermodynamic functions (entropy Sdt, Gibs Gdt, energy Hdt, Qdt) at depth h.
Figure 8
Figure 8
A detail of distribution curves of thermodynamic functions (entropy Sdt, Gibs Gdt, energy Hdt, Qdt) at depth h.
Figure 9
Figure 9
Modelled thermo-mechanical curves (thermal point TDpoint, melt point Tmelt, stress σret, yield point Re) after thermal spraying at the dependence on depth h.
Figure 10
Figure 10
Distribution of the interface depth layers hmelt classified by Tmelt at the relative depth hrel.
Figure 11
Figure 11
The dependence of the melting depth hmelt on the melting temperature Tmelt.
Figure 12
Figure 12
Modelled curved of Rmp (RmpSUB substrate materials—blue, RmpXY interlayers—green and RmpX overlay spraying layers—red) depending on the number of experiment ExpNo.
See this image and copyright information in PMC

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