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Wear 301 (2013) 102–108

Contents lists available at SciVerse ScienceDirect

Wear
journal homepage: www.elsevier.com/locate/wear

Abrasive impact wear and surface fatigue wear behaviour


of Fe–Cr–C PTA overlays
Renno Veinthal a,n, Fjodor Sergejev a, Arkadi Zikin a,b, Riho Tarbe a, Johann Hornung c
a
Department of Materials Engineering, Tallinn University of Technology, Ehitajate tee5, 19086 Tallinn, Estonia
b
AC2T research GmbH, Viktor-Kaplan-Straße 2, 2700 Wiener Neustadt, Austria
c
Castolin Gesellschaft GmbH, Industriezentrum NÖ-Süd Straße 14, Objekt M24 2355 Wiener Neudorf, Austria

a r t i c l e i n f o a b s t r a c t

Article history: The conventional Fe–Cr–C overlay is studied due to the lack of information regarding the response of
Received 15 September 2012 this material system to impact wear conditions. Previously the same material system has been
Received in revised form successfully used in erosion wear conditions. The high stress abrasive impact wear resistance and
17 January 2013
low and high surface fatigue wear behaviour of a Fe–Cr–C overlay (FeCrC—matrix) produced by plasma
Accepted 25 January 2013
transferred arc welding (PTA) were studied.
Available online 14 February 2013
The overlays with varied PTA hardfacing process cooling parameters were tested. The cooling
Keywords: parameters were as follows: (1) active cooling—application of gas cooling of substrate during the
PTA hardfacing welding process; (2) passive cooling—application of copper plate under substrate with constant
Fe–Cr–C hardfacing
temperature of 20 1C and (3) standard—cooling in the air. Different cooling time leads to differences in
Surface fatigue wear
microstructure and formation of residual stresses (surface cracks, etc.).
Abrasive impact wear
The abrasive impact testing reveals the difference in the overlays response to the cyclic stressing at
high impact energy. The surface fatigue wear (SFW) testing is accompanied by the abrasive impact wear
(AIW) testing. The SFW incorporates cyclic loading of the overlays surface with spherical indenter with
radius of 10 mm at high loads, while in AIW testing the specimens are bombarded almost in normal
direction with granite gravel particles (diameter of o 6 mm) with the energy in the range of
0.14–0.52 J.
The study proposes the relation between high energy impact/abrasive wear behaviour and the
surface fatigue wear behaviour of Fe–Cr–C hardfacings produced under varying cooling conditions.
& 2013 Elsevier B.V. All rights reserved.

1. Introduction indicated that it overshadows such internal parameters as size and


spacing of reinforcement particles. Also the size of the reinforcement
Core components such as crushers are exposed to heavy and the spacing between reinforcements has earlier been found to
impact wear and require efficient surface protection measures affect the wear rates. No direct conclusion can be drawn upon the
to avoid costly downtimes and to reduce costs for expensive spare wear performance of a specific alloy as the wear of each composite
parts. Wear resistance against abrasion and/or impact are often has to be evaluated separately, mainly because different types of
required to extend the lifetime of machinery equipment effi- reinforcement have different effects on composite wear rate as a
ciently [1]. Several studies have been conducted for investigation function of reinforcement volume fraction [3].
of wear mechanisms and suitable material combinations for The plasma transferred arc welding method, PTA, was devel-
impact wear conditions typical to crushers, mixing and milling oped in the 1960’s from the plasma arc welding method, PA. The
equipment [2,3]. PTA process exhibits enormous potential because the PTA over-
The relationships between wearing motion and wear mechan- lays have a lower production cost and a higher productivity
isms are affected by reinforcement-related parameters and matrix compared to thermal sprayed coatings, as well as easy operation
material. The importance of internal microstructural parameters in and no need for any special surface treatment [5–8]. This is
composite wear has been noted, e.g., by Berns [4]. The reinforcement because one of the main features of the PTA welding method is
type is noticeably a strong factor in material wear. It has been the low dilution of the deposit, which is from 3% to 10%. The low
dilution enables the use of single-pass layer to achieve the
intended deposition properties [9].
n
Corresponding author. Tel.: þ372 6203351. Fe-based alloys are used under severe conditions where
E-mail address: renno.veinthal@ttu.ee (R. Veinthal). erosion or abrasion are the main degradation mechanisms [1].

0043-1648/$ - see front matter & 2013 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.wear.2013.01.077
R. Veinthal et al. / Wear 301 (2013) 102–108 103

High chromium white irons (CWIs) and Fe–Cr–C overlays have The PTA processing parameters were optimized and are
been widely applied in areas where erosive degradation is a related to the welding behaviour taking into account the defects
common occurrence [10]. It has been reported by Kirchgaßner of produced weld seam (porosity and cracks), microstructure and
et al. [1] that in heavy impact applications, martensitic structures dilution with substrate. The optimized hardfacing parameters for
based on Fe–Cr–C alloy containing finely precipitated Niobium every cooling condition are listed in Table 1.
carbides behave best. A comprehensive microstructural evaluation of the plasma
The main alloying elements used to produce the Fe–Cr–C PTA hardfacing was carried out by optical microscopy (OM) equipped
overlays are chromium, Cr (11–35%) and carbon, C (1.8–6%); the with a digital camera (MEF4A, Leica Microsystem).
wear resistance of the alloys is achieved by the presence and
distribution of carbides in the ductile matrix [4]. The Fe–Cr–C
2.2. Wear testing apparatus
alloys can present a hypoeutectic, eutectic or hypereutectic
structures depending on the content of alloying elements and
2.2.1. Surface fatigue wear (SFW)
the solidification process [11].
The problem of bodies in contact was formulated by Hertz and
In many previous studies it was reported that changes in
is known as the Hertzian contact problem. The solution for half
process parameters can influence wear behaviour of Fe–Cr–C
space body (in our case spherical indenter) in contact with plane
hardfacings. However there is no information in literature found
(overlays plane surfaces) is well described and analytically simple
about influence of cooling speed on the properties of Fe–Cr–C PTA
(Eqs. (1)–(4)).
overlays. Therefore the main aims of present research are to study
Main information obtained from such solution is the stress–
the high energy impact/abrasive wear behaviour and the surface
strain curve or pressure depth dependences. The indentation
fatigue wear behaviour of Fe–Cr–C hardfacings produced under
stress can be calculated by formulae if contact radius a, contact
variation of cooling conditions.
between indenter and surface of the studied coating, is known
P
pm ¼ ð1Þ
pa2
2. Experimental
The mean contact pressure can be calculated, if the indenta-
2.1. Materials and welding parameters tion strain a/R can be defined and elastic mismatch factor k for
indented material and indenter is available, as
The Fe–Cr–C ( 44% C; 20–22% Cr; max. 2% Si, S, P; rest Fe) alloy  
3E a
powder was used in the present research as initial material for the pm ¼ , ð2Þ
4pk R
PTA process.
PTA hardfacing was performed using a EuTronics Gap 3001 DC where E is the elastic modulus of the indented material and R is
apparatus (Fig. 1). the radii of the indenter.
The welding was performed in a single layer. Mild steel 1.0037
with thickness of 8 mm was used as substrate. The deposition
of Fe–Cr–C was performed under simulation of different cooling Table 1
conditions, where the temperature of substrate material was Welding parameters of the Fe–Cr–C hardfacing alloys using different cooling
controlled during hardfacing process. The cooling conditions were parameters.
as follows: (for sample K1) standard—cooling in the air; (for the
Parameter Cooling conditions
sample K2) passive cooling—application of copper plate under
substrate with constant temperature of 20 1C; and (for the sample K1 (standard) K2 (passive) K3 (active)
K3) active cooling–application of gas cooling of substrate during
the welding process. Welding current [A] 90–110 90–110 90–110
Oscillation speed [mm/s] 25–30 25–30 25–30
Oscillation width [mm] 20 20 20
Welding speed [mm/s] 0.6–0.8 0.6–0.8 0.6–0.8
Distance torch/part [mm] 9 9 9
Plasma gas, Ar [l/min] 1.3–1.5 1.3–1.5 1.3–1.5
Cooling time 800–500 1C [s] 88 63 15

Table 2
Surface fatigue wear (SFW) testing conditions.

Feature/parameter Description

Available Tested

Distance from centre of the disk to 210


the point of impact of hammer [mm]
Number of hammers [pcs] 1–12 6
Impacting mass of the hammer [g] 10–160 67.4
Frequency of disk rotation [Hz] 1–20 3
Frequency of the impacts [Hz] 1–240 9
Speed of the hammer in the impacting 1.3y25.0 1.98
point [m/s]
Energy of the impact [mJ] 3–500 132
Ball (indenter) diameter [mm] 3–30 10
Material of the indenter Zirconium
oxide (97% ZrO2 and 3% MgO)
Fig. 1. PTA welding plant at AC2T research GmbH.
104 R. Veinthal et al. / Wear 301 (2013) 102–108

The contact radius a can be calculated according to the All experiments were conducted in air at room temperature
Hertzian contact solution by (2072 1C) with a relative humidity (RH) of 45 75%.
In the present study spherical indenter made of zirconium
4 kPR oxide (see Table 2) with diameter of 10 mm, commercially
a3 ¼ , ð3Þ
3 E available from RedHill Inc was used. The elastic modulus of the
where k is the elastic mismatch factor of the materials in contact, indenter is 195 GPa, and Poisson’s ratio is 0.27, as stated by the
and can be calculated as producer. This data was used in following calculations.
At least three tests for every number of cycles, starting from
 
9 E 103 up to 106 cycles, were performed for each Fe–Cr–C PTA
k¼ ð1n2 Þ þ 0 ð1n02 Þ , ð4Þ
16 E overlay. The energy of impact was selected as 132 mJ to replicate
high loads in the contact between tested overlays and indenter.
where E, E0 , n and n0 are the elastic modulus and Poisson’s ratios of
the material and the indenter correspondently.
The surface fatigue wear tests were performed using the 2.2.2. Abrasive impact wear (AIW)
surface fatigue wear tester designed and produced in Tallinn Abrasive impact wear (AIW) of the PTA overlays was deter-
University of Technology (TUT) for single spot testing. The mined with an experimental impact tester DESI developed in TUT.
detailed description of the system is given elsewhere [12], main Disintegrator type impact tester (Fig. 3) consists of one rotor with
parameters used in this study are given in Table 2. The dynamic impact members—fingers (14 fingers on a row) with the speci-
load in the test rig is transferred from the hammer that is mens fixed on them. Abrasive material—granite gravel was fed in
connected to, and accelerated by the rotating disk. The schematic the central part and moves from feed blades to impact members.
representation of the surface fatigue wear tester is shown in Wear rate Im in milligram per kilogram was determined as the
Fig. 2. The transferred energy of impact (impulse up to 500 mJ) mass loss of the target sample per mass of abrasive particles and
depends on the speed and mass of a hammer and can be adjusted was calculated as follows:
as needed. Several hammers (maximum number is 12 pcs.) can be
Dmbst hst
fastened on the periphery of the disk allowing increase of the Im ¼ ð5Þ
AQ w
frequency at least up to 240 Hz. The affordable frequency of the
impact is higher than that of hydraulic or electromagnetic testers where Dm is the average mass loss (mg), bst the standard
and the energy is higher than that of pneumatic ones. working zone width of the specimen (15.0 mm), hst the standard
The test set-up enables studying of materials behaviour under working zone height of the specimen (16.3 mm), A the average
conditions of dynamic compressive stresses (flat-to-flat contact) active surface area of the specimen (A¼bh, where b and h are the
average width and height of the specimen subjected to wear,
respectively); Q the mass of abrasive used in the experiment (kg)
and w the fraction of abrasive material allocated for a specimen.
The AIW was determined at three different particle velocities
(40, 60, and 80 m/s) corresponding to the impact energies of 0.14,
0.27 and 0.52 J. In the experiments 15 kg of granite gravel was
used with particle size o6 mm. (Fig. 4). The estimated impact
angle was about 901. Fraction of abrasive material allocated for
specimen (w) is determined by the computational method com-
bined with the graphical analysis. In a simplified manner it can be
stated that the mass of abrasive colliding with a single specimen
is proportional to total mass of abrasive like 9.41 out of 3601.
Detailed explanation of the calculus method is given in [13].
Fig. 2. Surface fatigue wear tester. A set of reference material (specimen made of mild steel) was
included in all AIW test to verify the stability of the test. The
specimens were cleaned with acetone and compressed air and
weighed with an accuracy of 0.1 mg before and after tests. Before
the primary test the specimens were subjected to wear-in process
in the same conditions to achieve the steady rate wear regime.
The standard testing mineral material was granite gravel. For
the calculation of kinetic energy, 50 g of granite gravel was
weighed and individual granite particles were counted. It was
found, that 50 g of granite gravel contained 318 particles in
average. Average mass per particle was determined by
mabr
mp ¼ ð6Þ
n
where mp is the mass of a particle, mabr is the total mass of
abrasive particles, n is the number of particles (counted), he is the
kinetic energy of a particle by contacting the 1st circle of the pins
can be calculated by

mp v2 50  103  58:32
Epk ¼ ¼  0:27 J ð7Þ
2 318  2
Kinetic energies for other rotational velocities are calculated in
Fig. 3. Abrasive impact wear tester. the same way.
R. Veinthal et al. / Wear 301 (2013) 102–108 105

Fig. 4. Granite gravel used in AIW tests (a) micrograph and (b) particle size distribution obtained by sieve analysis.

Fig. 5. OM micrographs of Fe–Cr–C hardfacings: K1 is standard cooling conditions; K2 is passive cooling conditions; and K3 is active cooling conditions.

3. Results and discussion highlighting fine-grained primary carbides as shown in Fig. 5 for
sample K3.
3.1. Microstructure and mechanical properties The rapid cooling speed can be correlated with the amount of
primary M7C3 carbides and undissolved Fe–Cr–C particles in the
Fig. 5 illustrates the typical cross-sectional OM micrographs of matrix. According to the quantitative analysis, using X-ray diffrac-
the coatings produced based on varying cooling conditions. It was tion analysis yielded the approximate amount of phase M7C3 in K1
found that different cooling times can lead to the significant at 55 wt%, in K2 at 51 wt% and in K3 at 39 wt%; the amount of
changes in the material microstructure. Hardfacing produced by Fe–Cr–C particles for hardfacing were K1—5 wt%, K2—11 wt% and
standard cooling conditions (K1) exhibits typical hardphases-rich K3—16 wt%. X ray diffraction (XRD) analyses were performed on an
hypereutectic structure. The carbide phases are presented in two X’Pert powder diffractometer (PANalytical, Netherlands) using CuKa
different shapes: hexagonal plated morphology and spine-like radiation in the Bragg–Brentano geometry at 40 kV and 30 mA.
shape, forming M7C3 proeutectic carbides [14]. Certain amount of The measurements were conducted in the continuous mode.
undissolved initial Fe–Cr–C particles was also detected. Modulus of elasticity E, is the measure of materials ability to
For the hardfacing, which was produced under active cooling sustain the elastic deformation. Material with higher elastic
conditions (K3), there is significant changes found in the micro- modulus can absorb more energy during loading and can be
structure, especially in the size of primary carbides. It was found classified as more stiff material.
that the average size of carbide particles decreased about factor of The modulus of elasticity is commonly used for assessment of
4 during the process. This can be attributed to the increased the wear resistance of coatings (films) for tribological applica-
cooling speed during hardfacing process. As a result, a fine- tions, especially in combination with hardness H. There are three
grained microstructure is achieved. Additionally, it should be main parameters proposed for analysing the coating wear beha-
outlined that the amount of undissolved Fe–Cr–C particles is viour. The H/E ratio is related to the elastic strain to failure of the
increased. This can also be correlated with the time required for coating [15]. The resistance of the coating to plastic deformation
the solidification of welding seam during hardfacing. Active is associated with parameter H3/E2. The fracture toughness of the
cooling conditions lead to extremely rapid cooling and as a coating can be related to empirical parameter (H/E)1/2 [15].
result to more pronounced refinement of the microstructure, According to Hill’s theory the (E/H)1/2 is related, and equals, to
106 R. Veinthal et al. / Wear 301 (2013) 102–108

the r0/b ratio (r0 is the cavity radius and b is the plastic zone coatings [17–19] and engineering ceramics [20]. The response of
radius). We propose to designate H/E 1/2 as the toughness ratio as the material to the cyclic indentation in some way reproduces the
it can be linked with the plastic zone radius and allows comparing repeated contact between two wearing components. Similar
overlays considering the deformation work or potential driving contact conditions can be found from lot of applications, like
force of the crack formation. All these parameters for studied bearings, stamping and cutting tools, machine part in contact
coating are summarized in Table 3. under high loads.
The elastic modulus for studied coating systems was measured The graphs representing the mean contact pressure depen-
with the use of sharp indentation (Vickers pyramid) according to dence on the indentation strain for studied Fe–Cr–C PTA overlays
the procedure proposed in [16] and using a testing system Zwick are shown in Fig. 7. The coating K1 seems to have the most
Z2.5 equipped with a universal hardness measurement head. The promising behaviour as the first straining starts at the high
comparative load–displacement (P–h) curves for Fe–Cr–C PTA pressure level if compared with other overlays, and K1 sustains
overlays are shown in Fig. 6. the highest pressure at moderate strain of 0.08 mm/mm.
The K2 overlay has the highest hardness and relatively high The indent depth is the smallest for K3 overlay as it has the
elastic modulus compared with two other Fe–Cr–C PTA overlays highest elastic straining response to the contact and the fracture
described in current study. The above mentioned parameters toughness parameter ((H/E)1/2, see Table 3) is comparatively high.
linking the wear behaviour and mechanical properties of coatings Coating with the lowest elastic response and the lowest resis-
are most fortunate in case of K2 overlay. This can be attributed to tance to plastic deformation—K3 is obviously the worst perfor-
better performance of K2 overlay in surface fatigue wear (SFW) mer at this case.
and abrasive impact wear (AIW) testing at relatively high loads. It is possible to see how the performance is changed in the
Indentations at the loads of 200 and 300 N were performed to sense of cyclic loading (see Fig. 8). The competition between
find the stable repetition in the results, and to provoke sufficient different overlays is most tough at the relatively high number of
plastic deformation in the overlays. All indentations were loading cycles, starting from about 50,000 cycles.
repeated at least three times. The mean contact pressure becomes almost equal after 105
The indentation curves (Fig. 6) are distributed in logical cycles. The K2 overlay shows the highest mean contact pressure
sequence in regard with hardness, but wear resistance to plastic value after maximum number of cycles of the test (106 cycles).
deformation ratios (H3/E2) are very similar for K1 and K3 overlays, The relatively low performance at low number of cycles ( o105)
and are most favourable for K2 overlay. of K2 can be associated with the smaller size of primary carbide
phase. After the number of contact cycles reaches certain thresh-
3.2. Surface fatigue wear (SFW) test results old value (which is 105 at this impact energy) the binder will be
extruded and the area of contact area increases thereby reducing
Repeated loading at the same point proved to be an effi- the contact stresses involved.
cient technique for assessment of the contact behaviour of the

Table 3
Relationships between tribological behaviour and mechanical properties of the
coatings studied.

Coating Hardness Elastic Elastic Resistance to Toughness


H [MPa] modulus E strain plastic deformation ratio
[GPa] ratio ratio
H/E H3/E2 (H/E)1/2

K1 7070 716 1627 0.33 0.0436 13.47 0.209


K2 7425 723 1627 0.34 0.0458 15.59 0.214
K3 6260 718 1357 0.10 0.0463 13.44 0.215

Fig. 7. The indentation strain of the tested overlays under mean contact pressure.

Fig. 6. Indentation load–displacement curves for studied Fe–Cr–C PTA overlays at Fig. 8. Dependence of the mean contact pressure on the number of cycles for
300 N load. overlays in the Hertzian contact.
R. Veinthal et al. / Wear 301 (2013) 102–108 107

Fig. 9. Largest indent (after 106 cycles of loading) for Fe–Cr–C PTA overlays tested in the SFW test.

Fig. 10. The fatigue striations in the K1, K2 and K3 overlay on the edge of the contact after the SFW test.

The fractographic investigations have shown that the K1


overlay has less visible damage sites within or near the indenta-
tion site, see Fig. 9. It can be attributed to its lowest H/E value
which is commonly associated with good performance in impact
wear conditions.
The cleavage marks are visible mostly near the centres of the
indent and on the contact circle, in the zone of the maximum
tensile stresses. The traces of the cyclic straining in this area are
visualized by K1 and K2 (Fig. 10). Same marks of fatigue striations
can be found in each overlay, but less of them are visible on the
surface of the K1 overlay (Fig. 10).

3.3. Abrasive impact wear (AIW) test results

The AIW test confirmed the results obtained by the SFW test.
The wear rate of PTA overlay fabricated using active cooling K3 Fig. 11. Dependence of AIW rate on impact energy of abrasive particle.
showed about 10—15% higher wear rate compared to those made
by standard (K1) or passive cooling (K2), as shown in Fig. 11. In
the current study K2 has the highest H/E1/2 ratio, and a compar-
ably high ability to withstand plastic deformation.
Microcracks can be seen in the carbides Fe–Cr–C on the wear
surface of the sample K1 in Fig. 12. The existence of microcracks
can be closely related to the formation of spalling pits.
During the AIW test, samples experienced a combination of
impact, ploughing and cutting. With the growth of the micro-
cracks, the Fe–Cr–C reinforcement particle would spall off and
leave a spalling pit on the surface. As active cooling leads to the
biggest amount of the Fe–Cr–C carbides (up to 16 wt%) it can
explain lower performance of material K3 in AIW tests. On the
other hand material K3 contains only 39% M7C3 type of carbides
which may make it more vulnerable to ploughing and cutting
compared to materials K1 or K2, containing 55 and 51% M7C3 type
of carbides, correspondingly. The difference in performance
becomes more evident with higher impact energies. Another
factor, influencing the wear performance of PTA overlays is
residual stress state which according to visual observations
leads to crack formation trough the overlay. In the current study Fig. 12. Fractured carbide of sample K1 in the AIW test at 40 ms  1.
108 R. Veinthal et al. / Wear 301 (2013) 102–108

K1 in AIW test at 60 ms-1 K1 in AIW test at 40 ms-1

Fig. 13. Fractured carbide of sample K1 in the AIW test at 40 and 60 ms  1.

(AIW test energies varying 0.14–0.52 J) it cannot associate with of Niederösterreich). Authors are also grateful to Castolin Eutectic
the lower performance of K3 overlay. GmbH for helpful work and providing powder materials. Student
The whole area of specimen shown in Fig. 13 is covered with mobility has been supported by graduate school ‘‘Functional
small dimples, the ductile tearing sites, and traces of severe materials and technologies’’ receiving funding from the European
plastic deformation of the surface. The carbide phases are crushed Social Fund under Project 1.2.0401.09-0079 in Estonia.
being impacted by large abrasive particles and the brittle fracture
takes place. The cleavage facets are marked with white arrows
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