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Original article

Neural network supported study on erosive wear performance analysis of

Y2O3/WC-10Co4Cr HVOF coating

Jashanpreet Singh, Simranjit Singh

PII: S1018-3639(21)00176-8
DOI: https://doi.org/10.1016/j.jksues.2021.12.005
Reference: JKSUES 592

To appear in: Journal of King Saud University - Engineering Sci‐

ences

Received Date: 15 July 2021

Revised Date: 28 November 2021
Accepted Date: 8 December 2021

Please cite this article as: Singh, J., Singh, S., Neural network supported study on erosive wear performance
analysis of Y2O3/WC-10Co4Cr HVOF coating, Journal of King Saud University - Engineering Sciences (2021),
doi: https://doi.org/10.1016/j.jksues.2021.12.005

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Neural network supported study on erosive wear performance analysis of

Y2O3/WC-10Co4Cr HVOF coating

Jashanpreet Singh1*, Simranjit Singh2

1Department of Engineering, Punjab State Aeronautical Engineering College, Patiala 147001, Punjab,

India
2Department of Computer Science, Bennett University, Greater Noida 201310, Uttar Pradesh, India

*Corresponding author’s email: jashanpreet.singh@mrsptu.ac.in

ABSTRACT
In this work, a study was carried out by modifying the conventional WC–10Co4Cr powder with a small addition of yttrium-oxide (Y2O3).
Reinforcement was done by the addition of Yttria (Y2O3) ceramics in WC–10Co4Cr powder by using a jar ball mill process. The surface
microstructure, chemical composition, and phase compositions of coating powder and coatings were examined by using scanning electron
microscopy, energy dispersive spectroscopy, and X-Ray Diffractometry. Silt erosion is assessed through a pot tester by preparing the equi-
sized and multi-sized slurries at different velocities, impact angles, concentrations, and rates. Results show that the WC–10Co4Cr coating
reinforced by Y2O3 ceramics possesses low porosity and provides higher erosive performance as compared to conventional WC–10Co4Cr
coating. The present study reveals that the deposition of conventional WC–10Co4Cr coating helped to improve the wear resistance of AISI
316L steel by 9.98% for the variation in rotational speed. However, the erosive wear performance of conventional WC–10Co4Cr coating was
improved by 45.9% by blending with the Y2O3 ceramics.

Keywords: Neural networks, Machine learning, Erosion, Wear, HVOF technique.

1. INTRODUCTION 2016). The high-velocity oxy-fuel (HVOF) spraying process is

Erosive wear is a branch of tribology science which deals with the
interaction between the metal or composite (target material) and
solid-liquid (i.e. slurry) (Prawoto, 2013; Singh et al., 2020). Due to
the interaction between metal and slurry, the slurry particles
deteriorate the surface of the metal by the means of mechanical
action caused due to the transfer of kinetic energy from particles to
the metal surface. Practically, this phenomenon is analyzed in a
wide range of industries such as chemical, mining, and food
processing industries as well as in hydro/thermal power plants.
The performance of hydraulic machinery and its components is
severely affected by the erosive problem caused by liquids or solid-
liquids (Al-Hashem et al., 1996; Islam, 2021; Obaseki et al., 2021;
Singh et al., 2020). In thermal power plants, three solids are
conveyed through centrifugal slurry pumps by preparing slurry for
example fly ash and bottom ash to dyke areas and coal for
electricity generation. Sand silt is also transported in the mining
industry employing heavy-duty centrifugal slurry pumps. In
various industries, the erosive wear is caused by solid particles
which predominantly affect the efficiency of the slurry pumps
(Kamaraj, 2008). Slurry pumps are fabricated by using stainless
steel (Dawoud and El-Naggar, 1996). In these severe conditions,
the life of steel-made components can be only increased by
reducing the erosive wear. Moreover, the solids conveyed through
slurry pumps are entirely dissimilar from each other (Singh,
2021a). For instance, the shape, hardness, size, physicochemical
properties of these solids are indifferent. So, the amount of wear
and wear mechanism by these slurries presents a unique nature.
Various types of coating processes are used in industries for
preventing the material deterioration of hydraulic machinery.
Different disposition methods like twin wire arc spray, cold spray,
detonation gun spray, and atmospheric plasma spray techniques
are used to deposit the WC–CoCr coatings (Reddy et al., 2017,
universally adapted by different industries to protect the hydraulic
machinery from erosion, corrosion, and abrasion damages. In this
process, the powder particles are injected at a very high velocity
and kinetic energy. In various industries, the HVOF technique is
adapted for the protection of the materials which are imposed on
accelerated conditions. Usually, the HVOF spraying is performed
at a particle velocity of ≈ 500 m/s below temperature 3000 K.
With the HVOF-process it is possible to produce coatings, which
can protect hydraulic components against erosion (Buytoz et al.,
2013). From comparative analysis with other techniques like wire
arc spraying and plasma spraying technique, it is found that the
HVOF technique is promising in terms of providing better
properties like lower porosity and amorphicity, and high hardness.
The formations of oxides are also lower in the case of the HVOF
technique (Cherigui et al., 2004; Hong et al., 2014; Vignesh et al.,
2017). In actual practice, the WC-Co coatings deposited by using
cold spray techniques are widely applied in marine applications at
lower temperatures, e.g. ship propellers (Peat et al., 2017). The
brittle coating layer with poor bond strength is achieved from the
cold spray coating technique. It is also difficult to make a coating of
complex shape powders by cold spraying method (Karthikeyan,
2007; Tang et al., 2018; Yin et al., 2017).
Many researchers have scientifically proved that WC–
17Co, WC–12Co, and WC–10Co4Cr coatings help to reduce the
drastic effect of slurry erosion. Simply Co-bound WC coatings (for
example, WC–12%Co and WC–17%Co) are usually adapted in
primary requirements where the corrosion is inconsiderable
(Berger, 2015; Davis, 2004). From recent studies carried out on the
HVOF technique, it is revealed that the commercial WC-CoCr is
used in a variety of industrial applications to improve erosion and
corrosion performance (Maiti et al., 2007; Wheeler and Wood,
2005). Microstructure features (like porosity, phase distribution,
carbide dissolution), erosion resistance, and corrosion resistance
are investigated in numerous studies (Fedrizzi et al., 2007;
Houdková et al., 2011; Maiti et al., 2007; Thakur and Arora, 2017;
Wheeler and Wood, 2005). However, in recent years, the
improvement in the performance of WC-Co and WC–CoCr
coatings is made it very popular amongst investigators. In previous
studies, the addition of feedstocks like Nano-sized WC (Thakur
and Arora, 2017), Nano- and micro- WC–Co (Cho et al., 2008),
Yttria ceramic (Nath and Kumar, 2018), Nano-sized WC–12Co (Liu
et al., 2010), TiO2, etc. was attempted by different investigators.
Thakur and Arora (2017) investigated the erosive wear
performance of Nano WC–CoCr coating using a pot tester. This
study includes the use of multiwalled carbon nanotubes for
improving the adherence strength of Nano WC–10Co4Cr. Results
indicated that Nano WC grains in WC-10Co4Cr coating provided a
better erosive resistance than the micro WC-10Co4Cr coating. Cho
et al., (2008) investigated the mechanical properties of Nano (n)
and micro (µ) WC–Co powders sprayed by the HVOF process.
Results show that the n-WC–Co powder produced a denser and
harder as-sprayed surface as compared to µ -sized WC-Co powder.
Nath and Kumar (2018) studied the erosive wear of 13Cr–4Ni steel
by spraying the WC–10Co4Cr coating. Results showed that the
erosive wear resistance of WC–10Co4Cr cermet coating was
improved by the blending of micro-sized yttrium oxide.
Investigators have made several attempts for the betterment of the
mechanical behavior of coatings with the addition of harder and
brittle materials. In previous studies, Yttrium oxide (Y2O3) is used
as a reinforcement in several materials such as Ti-Ni alloy (Ahmadi
and Nouri, 2011), sintered WC/Co composites (El-Kady, 2013),
13Cr-Ni steel (Nguyen et al., 2010), bioactive glass-ceramics (Al-
Haidary et al., 2008), aluminum (Bouaeshi and Li, 2007), etc.
Artificial Intelligence (AI) is a powerful machine and it
functions just like a human. AI is the concept encompassing all the
advancements in computer science, with its emphasis on intelligent
and evolving actions. In a broad sense, AI may be considered to
include artificial structures such as algorithms and forms as the
concept was first introduced at Dartmouth University (1956)
(Brownlee, 2011; Moor, 2006). A strong artificial intelligence
behaves like a human in the sense that it resembles the human
brain in its cognitive layers (Frochte, 2019). Artificial Neural
Network (ANN) is a class of networks that is based on learning
(Singh and Singh, 2021). ANN imitates the function of neurons
present in the human brain to establish the learning process.
Hayman, (1999) presented a simple mathematical model that is
divided into two parts. The first part takes the input and performs
the operations whereas the second part predicts the outputs. But
there is an underlying problem with this model is that it does not
have any learning process because there are no weights assigned.
Rosenblatt (1958) developed another model called perceptron
which have weights assigned to the edges. Due to the introduction
of weights, the perceptron could perform learning in the
Hebbean sense.
From the literature survey, it is revealed that the
improvement in mechanical properties like microhardness,
toughness, ductility, etc. also contributes to the improvement of
erosion resistance (Berger, 2015). High hardness is a significant
parameter that participates in the improvement of erosion
performance (García et al., 2019; Singh et al., 2018). Further, the
addition of various feedstocks helps improve the different
properties of WC–10Co4Cr coating (Cho et al., 2008; Liu et al.,
2010; Nath and Kumar, 2018; Thakur and Arora, 2017). In this
perspective, the present study is conducted to improve the erosive
performance of conventional WC–10Co4Cr coating by the addition
of Y2O3 ceramics powders. An artificial neural network (ANN)
model was developed for the prediction of erosive wear from the
specimens. In the previous study, the erosive wear of Y2O3
ceramics added WC-10Co4Cr HVOF coating was tested for fly and
bottom ash (Singh et al., 2019a). The present study is an
application of slurry pump and short-range pipelines circuits
where these coatings were applied to withstand the erosive wear
produced by the silt, fly, and bottom ash.
2. MATERIALS AND METHODS
2.1 Substrate
In the present investigation, the AISI steel was selected as a
substrate material and its nominal composition was checked by
using an optical emission spectroscope. The nominal composition
of AISI steel was tested as shown in Table 1. The schematic
geometry of the test specimen is illustrated in Fig. 1.
2.2 Coating and deposition
Thermal spraying powder namely WC-10Co4Cr was procured
from Parshwamani Metals, Mumbai (India). The Y2O3 was
purchased from the HPLC Pvt. Ltd. Srigam (India). The blending
was done by following the Jar milling process. Jar milling was
performed by using hardened steel balls having a diameter of 2 cm
and the process is followed for 2 hours. Coating deposition was
accomplished using high-velocity oxy-fuel (HVOF). Thermal
spraying was executed at Harsha Specialty Welding, Panchkula
(India). Before executing the coating process, a shot-blasting
process was done to prepare the surface of the specimen for
adherence. It was done with the help of the P7-150 unit (Fabricated
by Abrablast Equipment Private Limited, Jodhpur, RJ. India).
During the shot blasting, the quartz (30 to 80 mm) was used as an
abrasive which was shot from a distance of 200 mm from the
specimens by a 5 mm orifice.
2.3 Characterization methods
The scanning electron microscopy (SEM) technique was utilized to
study the morphology of erodents, coatings, and substrate
materials with the help of a JSM 6510LV scanning electron
microscope (manufactured by JEOL, The Netherlands). The study
of crystal structure was done on a PW-1710 Diffractometer
(manufactured by Philips X’pert, Enschede, The Netherlands)
using an X-Ray diffractometry technique i.e. XRD. A voltage of 40
kV was established at a current of 30 mA however, the Cu Kα was
used as a reference substance, and the intensity (λ) of produced
radiation was 1.542 Å. Microhardness testing of specimen material
and coatings was done with a précised MVH-1 tester
(Manufactured by the Metatech, Pune, India). The indentation
marks were measured from the optical image captured at a
magnification of ×400 an optical microscopy micrograph. The
reproducibility was satisfied by repeating the testing for 6 trials.
During the tests, the load of indentation was kept as 1000 g and
the time of dwell was taken as 20 sec. Microhardness of AISI 316L
steel was obtained as 211±15 HV.
3. EXPERIMENTS
3.1 Range of parameters
Slurry erosion experiments were conducted at different numbers of
rotational speeds and time durations. The layout of
experimentation preferred in the present work is summarized in
Table 2. For this study, the produced velocities (with propeller
shaft speed) are 600, 900, 1200, and 1500 rev/min. The mass flux
concentration of the two-phase slurry was kept in the range of 30-
60 wt%. During the erosive testing, the impingement angle was
varied to evaluate its influence on the slurry erosion.
 Fig. 1. Schematic geometry of the test specimen

Table 1. Nominal composition of AISI 316L steel

Elements S P C Mo Mn Si Ni Cr Co Fe
Percentage 0.005 0.083 0.005 1.69 1.02 0.135 10.35 16.60 1.69 Bal.

3.2 Slurry preparation 3.3 Slurry properties

The sand, fly ash and bottom ash particles were used as the erodent
materials to study the erosive wear phenomenon. The slurry was
prepared by taking the desired weight percentage of sand erodent
in water for example 30 wt%. After taking the desired weight
percentage, the slurry was mixed with a stirrer for 30-60 seconds
at a speed of 300 rpm. Then, the mixed slurry was poured into the
slurry pot in order to perform the experiments.
The specific gravity of the sand, fly ash and bottom ash was taken
as 2.667, 2.259, and 2.081 respectively (Singh, 2019). The
circularity factor (CF) value of particles was calculated in the
previous study (Singh et al., 2019b) and taken as 0.637, 0.908, and
0.712 respectively for the sand, fly ash, and bottom ash. The
weighted mean diameter of sand, fly ash and bottom ash particles
were evaluated as 195, 82.5, and 125 µm (round-off values)
respectively by using the British Standard sieves.

Table 2. Layout of experimentation preferred in present work

S. No. Rotational speed Concentration Time Impact angle
1 600 30 90 0
2 900 30 90 0
3 1200 30 90 0
4 1500 30 90 0
5 1500 30 180 0
6 1500 40 180 0
7 1500 50 180 0
8 1500 60 180 0
9 1500 60 90 0
10 1500 60 120 0
11 1500 60 150 0
12 1500 60 180 0
13 1500 60 180 0
14 1500 60 180 30
15 1500 60 180 45
16 1500 60 180 60
Note: This set of experiments is conducted for AISI 316L and both coatings by taking Sand erodent

Proximity sensor Motor shaft

0.5 HP (0.37 kW) motor

Base plate
Flange for
Shaft ring cooling

Impeller of 25.4 mm
diameter
Specimen

Slurry pot

Cooling vessel

Screw jack
 Fig. 2. Test setup used for the erosive wear experiments (Singh et al. 2020, permission of reproduction from Elsevier)
3.4 Equipment
Erosive wear experimentation was done on a Ducom pot tester
(Model: TR-41) at different speeds, times, and concentrations. The
test setup used for the wear experiments is shown in Fig. 2. In
order to perform the experiments, the slurry of a particular solid
concentration was poured into the pot of the tester. Then, the
rectangular specimen was screwed into the propeller shaft and the
height of the pot was adjusted by using the jack. The pot tester was
run to the desired period in order to perform each experiment to
analyze wear. The rate of wear was measured in g/m2 with respect
to the time. The experiments were conducted for sand erodent
only. However, the dataset of fly and bottom ash was taken from
the previous study (Singh et al., 2019a).
4. NEURAL NETWORK MODEL
In the recent past, in particular, the use of feedforward neural
networks was regular (Singh and Singh, 2021). The simulations
were performed on a PC having an Intel i5 processor with 12 GB
RAM and 512 SSD. The neural network model is built on
MATLAB software of version 2018b. The designed ANN contains
2 layers (hidden and output layer). Although, the input layer has 10
neurons and the adaptive learning function LEARNGDM is
employed. Detailed parameters of ANN are presented in Table 3.
The network arrangement is represented in Fig. 3. The present
neural network constitutes input, hidden, and output layers. ANN
has a feed-forward pass and a backpropagation pass. In
feedforward, each neuron in the next layer is calculated by
iteratively calculated by the following equation:
Oa  Wm a 1  b (1)
Where b is the bias and W is the weight assigned. Output
generated at the end was matched with the actual value to get the
error. Mean square error was used as a calculated error which is
also referred to as the cost function:
C
1
 yi  y 2 (2)
t Characterization of coating powders includes scanning electron
Similarly, in a backward pass, the error between the actual and
predicted output is minimized iteratively. The weights assigned to
the hidden layer are updated for this purpose. There are many
methods used for this in which gradient descent is mostly applied.
In the present work, the weights were assigned to the hidden layer
by using the following equations:
E  E   Y   neti 
Wij         (3)
Wij  Y   neti   Wiq 
 
Wij   di  yi  f ' neti  Z q   oi Z q (4)
In the above equations, symbol Y is the donated symbol of the
output value from the ANN model, and d donates the supplied
target value.
Fig. 3. Network arrangement of ANN
The designed ANN model was evaluated based on Mean Absolute
Error, coefficient of determination (R2), Root Mean Square Error
(RMSE), Pearson correlation coefficient (R), and Lin’s concordance
coefficient. Firstly, the input data is obtained with the help of
experimentation. The obtained data have 10 features including
rotational speed, concentration, static settled concentration, time,
impact angle, microhardness, coating porosity, specific gravity, CF
value, and weighted mean diameter. It is partitioned into training,
validation, and testing sets. 70% of the total data is given to the
ANN for supervised learning (training), 15% of data is given to the
ANN for validation. The validation set is very important for the
ANN for effective prediction. We can observe its performance on
the validation set, if it is not doing well, the model parameters are
tuned to get the highest performance. In the end, the built model is
given the remaining 15% of the unseen data as a testing set. Based
on the results of the model are evaluated on the basis of
performance metrics.
Table 3. Performance Comparison of ANN with GPR
Sr. No Parameters Values
1 Learning rate 0.01
2 Training function TRAINLM
3 Performance function MSE
4 Adaptive learning function LEARNGDM
5 Input Neurons 10
6 Total Layers 2
5. RESULTS AND DISCUSSIONS
5.1 Characterization of coating powders
microscopy (SEM) and X-ray Diffractometry (XRD) analyses. The
detailed discussion has been done in the following subsections:
5.1.1 Morphology of coating powders
Fig. 4 shows the typical microstructure of thermal spraying
powders. The surface microstructures of WC–10Co4Cr powders
demonstrate the spherical morphology. Moreover, the WC–
10Co4Cr powder possesses internal porosity, as seen in Fig. 4(a).
From the SEM micrograph (in Fig. 4b), it can be seen that the
Y2O3 exhibits a starched plastic-like shape. Due to blocky grains of
Y2O3 ceramics, the Y2O3 was reinforced into WC-10Co4Cr’s open-
pored surface, as seen in Fig. 4(c). The embedment of Y2O3
ceramics was confirmed in the XRD patterns, as shown in Fig. 5.
The distribution of Y2O3 ceramics was uneven on the surfaces of
WC-10Co4Cr particles due to an extremely low proportion. The
shape of WC-10Co4Cr particles remains unaffected after blending
due to the same region.
 Fig. 4. Morphology of (a) WC–10Co4Cr, (b) Y2O3 and (c) Y2O3 ceramics added WC–10Co4Cr powders

5.1.2 XRD of coating powders

Fig. 5 represents the XRD patterns of conventional and Y2O3
ceramics WC–10Co4Cr powders. XRD spectra of conventional
WC–10Co4Cr (Co-10% and Cr-4%) powder identified the
crystalline phases namely WC, W2C, Cr23C6, and CoC. The
crystalline phases identified in WC–10Co4Cr powder also hold a
close agreement with the previous studies (Maiti et al., 2007; Nath
and Kumar, 2018; Thakur and Arora, 2017). The XRD pattern of
Y2O3 reinforced WC–10Co4Cr powder shows the presence of
different crystalline phases like WC, W2C, Cr23C6, CoC, and α-
Y2O3. The crystalline phases identified in Y2O3 reinforced WC–
10Co4Cr powder also shows a close deal with the literature (Bolelli
et al., 2014; Nath and Kumar, 2018).

5.2 Coatings characterization

Coating characterization includes the analysis of surface and cross-
sectional microstructure (by using SEM), XRD, EDS area
mapping, and microhardness. The coating characteristics are
explained as follows: Fig. 5. XRD patterns of conventional and Y2O3 ceramics added
WC-CoCr powders

5.2.1 Surface microstructure of as-sprayed HVOF coatings

Fig. 6 represents the surface microstructure of as-sprayed
conventional and advanced WC–10Co4Cr. In SEM micrographs at
a magnification of ×2000, the combination of fully and partially
melted particles can be visualized which form the globules
microstructure i.e. splats. Furthermore, few un-melted particles
and pores are visible on the coated surface. However, the splats
produced the solid surface of coated specimens that reflects an
anisotropic surface (Mohammed Jasim, 2013). No crack is visible in
the SEM micrographs which represent the superior quality of
coatings.

Fig. 6. SEM images of as-sprayed (a) conventional and (b) Y2O3 ceramics added WC-10Co4Cr coatings, at high magnification ×2000
 Fig. 7. Cross-sectional SEM micrographs of as-sprayed (a) conventional and (b) Y2O3 WC-10Co4Cr coatings

5.2.2 Cross-sectional analysis of as-sprayed HVOF coatings 5.2.3 XRD of as-sprayed HVOF coatings
Cross-section SEM micrographs were generated to analyze the XRD patterns of conventional and Y2O3 ceramics WC–10Co4Cr
substrate-coating interface and thickness of coatings. Fig. 7 coating are represented in Fig. 10. XRD pattern of WC–10Co4Cr
represents the cross-section microstructure of coatings. In SEM coatings showed the identified crystalline phases namely WC,
micrographs, continuous contact between the coating and the W2C, Cr23C6, Co2W4C, and CoC. However, the Co2W4C phase
substrate can be observed which delivers the interfacial bonding. forms after the HVOF coating process. The present XRD results of
The formation of inter-lamellae splats on the substrate is quite WC–10Co4Cr HVOF coating showed a good agreement with the
often observed in thermal spray coatings. Inter-lamellae splats literature (Maiti et al., 2007; Nath and Kumar, 2018; Thakur and
ensure the interlocking between coating and substrate, Arora, 2017). Furthermore, the extensiveness of WC and W2C
consequently the high bonding strength, long life of coatings, and peaks in XRD patterns probably reflects the indigenous
superior mechanical properties (Li et al., 2015; Yao et al., 2016). distinctions in the W/C ratio.
The coating thickness of the as-sprayed coated surfaces was also
examined using an SEM technique. The coating thickness was
found in a range of 155–300 µm. The back-scattered X-ray energy
dispersive (EDS) mapping was used to visualize the elements
present in coated surfaces. EDS mapping was employed to the
cross-sectional axis of coated specimens. Fig. 8 and 9 show the
EDS maps of conventional and ceramics added WC–10Co4Cr
coating. In both coatings, the high percentage of Iron (Fe) can be
seen the AISI 316L substrate. High composition of Tungsten (W)
can be seen in both of the coatings. In Fig. 9, it can be seen that the
presence of the Yttrium (Y) was uneven in the coating layer.
However, the amount of Yttrium content per unit area seems
consistent.

Fig. 9. EDS map of Y2O3 ceramics added WC-10Co4Cr coating

Fig. 8. EDS map of conventional WC-10Co4Cr coating


Fig. 10. XRD patterns of conventional and Y2O3 ceramics added WC-
10Co4Cr coatings
5.2.4 Coating porosity
The porosity of the coated surfaces was evaluated by using the
water immersion method (Dullien, 1992). As per this method, the
coating specimen was weighted in dry condition. Afterward, it was
immersed in water for 2-3 minutes then cleaned with the tissue
paper and exposed to air for 2-1-2 minutes. It can be assumed that
the water inside the pore region cannot evaporate easily. This
specimen is again weighted. Therefore, the readings are put to
calculate the pore volume. The pore volume is calculated by:
Ws  WD
V (5)
 water
In the above equation, the Ws represents the weight of the
saturated specimen and WD represents the weight of a dried
specimen. The porosities of conventional and Y2O3 ceramics added
WC–10Co4Cr coatings were found as 0.934±0.023 and
0.509±0.019% respectively in four trails. Porosity results indicate
that the blending of yttrium-oxide is effective for the densification
of WC–10Co4Cr coating.
5.2.5 Microhardness of as-sprayed HVOF coatings
Besides, the microhardness of the coatings was examined across
the cross-section of specimens. The maximum microhardness
measured for conventional and Y2O3 reinforced WC–CoCr coatings
were 1156, and 1123 HV respectively. The microhardness Y2O3
improves with an increase in deposition temperature (Colen and
Bunshah, 1975). It was reported in the literature that the hardness
Y2O3 was found 502 HV while depositing at 720°C (Colen and
Bunshah, 1975). The microhardness of the AISI 316L steel
substrate and substrate/WC-10Co4Cr coating interface was also
examined and found as 212±7.5 and 877.49±4.29 HV respectively.
The average microhardness of Y2O3 reinforced WC–10Co4Cr
coatings was found 817.41±6.94 HV at the substrate-coating
interface. However, the cooling rate during the HVOF spraying
continuously maintained to avoid the rapid heating of the test
specimens. It can be assumed that the work-hardening process
occurs during the grit-blasting of test specimens which enhanced
them higher hardness at interface region than that before coating.
5.3 Erosive wear results
5.3.1 Effect of rotational speed
Fig. 11 shows the results for the parallel slurry flow (0°)
experiments for which infers the influence of rotational speed on
the erosive wear. The result data indicates that the erosive wear is
strongly dependent on the rotational speed of the solid particles.
The rate of increase in erosive wear seems unequal with the
increments in rotational speed, and its curve doesn’t pass through
the slope of the graph. Regression was performed to fit the values
of exponents. The value of exponent ‘α’ was fitted as 1.8143 for
AISI steel whereas 1.2906 and 1.1284 respectively for conventional
and Y2O3 ceramics added WC–10Co4Cr coatings. The value of ‘α’
gives the significance of particles' motion with the erosion of
materials (Gandhi et al., 2003, 1999; Gupta et al., 1995). The value
of ‘α’ is recommended in the range of 1.0–2.5 (Elkholy, 1983;
Gupta et al., 1995). Three different conditions are reported in the
literature (Gandhi et al., 2003, 1999; Gupta et al., 1995) to signify
the value of ‘α’. Firstly, the erosive wear is directly proportional to
velocity if α = 1. Secondly, the augmentation of erosive wear is
non-linear with the increase in velocity if 1< α < 2. Lastly, the
erosive wear is directly associated with the kinetic energy of
striking particles if α ≥ 2. In present study, the second condition
satisfies i.e. 1< α < 2. Thus, the erosive wear was augmented
nonlinearly with the change in rotational speed. Additionally, it was
confirmed that solid particles didn’t rebound on these coatings. By
comparison, it was also noticed that the sand erodes more as
compared to the bottom and fly ash. However, the erosive wear by
bottom ash particles was higher than the fly ash particles.
Also, the Y2O3 reinforced WC–10Co4Cr coating
possesses low silt erosion as compared to conventional, and Mo2C
reinforced WC–10Co4Cr coating. Further analysis reveals that the
deposition of conventional WC–10Co4Cr coating has improved the
wear resistance of AISI 316L steel by 9.98%. The wear
performance results of WC–10Co4Cr coating show a close
agreement with previous investigations (Gupta et al., 1995). The
addition of Y2O3 reinforced WC–10Co4Cr coating was beneficial in
improving the wear resistance of conventional WC–10Co4Cr
coating. However, the erosive wear performance of conventional
WC–10Co4Cr coating was improved by 45.9% by blending with
the Y2O3 ceramics.
Additionally, Fig. 11 depicts that the erosive wear of test
specimens was amplified at a non-linear rate while the speed of
particles increases. This happened because the kinetic energy (KE)
of erodent rises at higher velocities. The erodent traveling at
higher velocities releases the KE to the test specimens at the
collision time; subsequently, the high erosion occurs (Gandhi et al.,
2003; Singh et al., 2018). However, the erodent moving at lower
velocity demonstrates a lower KE that results in lesser erosive
wear. Several investigators reported that the magnitude of erodent
velocity is the greatest amongst other parameters (Gandhi et al.,
2003, 1999; Singh, 2021b; Singh et al., 2018).
 Fig. 11. Erosive wear of bare AISI 316L, conventional WC-10Co4Cr and ceramics added WC-10Co4Cr HVOF coatings at different rotational speeds for (a)
sand, (b) bottom ash (Singh et al., 2019b), permissions of reproduction from Elsevier (c) fly ash (Singh et al., 2019b), permissions of reproduction from Elsevier.
[Note the constant parameters: concentration = 30% (by wt.), impingement angle = 0°, and testing time = 90 minutes]

Fig. 12. Erosive wear of bare AISI 316L, conventional WC-10Co4Cr and ceramics added WC-10Co4Cr HVOF coatings at different testing time periods for (a)
sand, (b) bottom ash (Singh et al., 2019b), permissions of reproduction from Elsevier (c) fly ash (Singh et al., 2019b), permissions of reproduction from Elsevier.
[Note the constant parameters: rotational speed = 1500 rpm, concentration = 60% (by wt.), and impingement angle = 0°]

5.3.2 Effect of testing time
Fig. 12 shows the effect of testing time on silt erosion during the
parallel slurry flow at an impingement angle is 0°. From Fig. 12, it
is found that an increase in the time duration results in higher
erosive wear. The order of erosion for coatings remains similar as
identified in the case of rotational speed variation. Additionally, the
evolution of the time vs. erosion curve was approximately linear in
manner. Results data also indicates that the erosion occurred with
a higher magnitude at the early phase of experiments and drops
rapidly afterward. In the present study, the early phase is indicated
as 90-120 min. For the testing time of 90-120 min, the
augmentation of wear was higher as compared to 120-150 min.
This augmentation further drops in testing time of 150-180 min.
This can be clearly visualized in the case of erosion curves of
coatings. It can be seen that the curve drops below the slope with
an increase in testing time. The reason behind the decrease of
erosion after a time passage is reported by many researchers in
different studies (Manisekaran et al., 2007; Singh et al., 2019b).
According to Ref. (Manisekaran et al., 2007; Singh et al., 2019b),
erosion is a collision-based process in which the hardness of the
target’s as well as striking particle material plays a crucial role.
The sand particles possess a high microhardness i.e. 330-360 HV
(Desale et al., 2008; Walker and Hambe, 2015). Additionally, the
properties of striking particles like angularity, size fraction, etc.
decrease with time during the erosion experiments (Singh et al.,
2020). The size distribution of erodent particles was done to find
the mean size fraction of particles after erosion wear. The mean
diameter of particles after erosion wear was found as ~119 µm.
Approximately 7% particles were found <53 µm, 9% particles in
range 53-75 µm, 22% particles in range 75-106 µm and 12%
particles in range 106-150 µm. However, 30% of particles were
found in the range 150-255 µm and only 10% of particles were
coarser than 255 µm. It can be perceived that the mean size fraction
of silt particles after experiments was found smaller than that of
fresh silt used for experiments.

Fig. 13. Erosive wear of bare AISI 316L, conventional WC-10Co4Cr and ceramics added WC-10Co4Cr HVOF coatings at different concentrations of erosive
slurry of (a) sand, (b) bottom ash (Singh et al., 2019b), permissions of reproduction from Elsevier (c) fly ash (Singh et al., 2019b), permissions of reproduction
from Elsevier. [Note the constant parameters: rotational speed = 1500 rpm, testing time = 180 minutes, and impingement angle = 0°]

Fig. 14. Erosive wear of bare AISI 316L, conventional WC-10Co4Cr and ceramics added WC-10Co4Cr HVOF coatings at different impingement conditions for
(a) sand, (b) bottom ash (Singh et al., 2019b), permissions of reproduction from Elsevier (c) fly ash (Singh et al., 2019b), permissions of reproduction from
Elsevier. [Note the constant parameters: rotational speed = 1500 rpm, testing time = 180 minutes, and concentration = 60% (by wt.)]

5.3.3 Effect of concentration
Fig. 13 presents the effect of erodent concentration on erosive
wear. From Fig. 13, it was noticed that the concentration was not
amplified through the slope, and its curve exhibit a non-linear rate.
Moreover, at the higher erodent concentrations, the increase in
particles’ volume per unit area leads toward the increase in the
number of localized attacks made by particles on the test specimen.
The value of exponent ‘β’ is fitted as 0.7891 for AISI 316L steel
whereas 0.7326 and 0.6058 respectively for conventional and Y2O3
ceramics added WC–10Co4Cr coatings. The value of exponent ‘β’
is found below 1 which signifies that the concentration curve
moves below the slope. This indicates that the concentration has a
lower effect on erosion as compared to the rotational speed.
5.3.4 Effect of impingement angle
Fig. 14 represents the effect of impingement angle on erosive
wear. During the experimentation, the impingement angle was
taken in the range of 30° to 60°. It was perceived that the erosive
wear attains a maximum value at an angle of 30º for AISI steel
whereas at a 60º angle for both coatings. The approach of erosive
wear indicates that the conventional and Y2O3 ceramics added
WC–10Co4Cr coatings show a pure brittle behavior.
Fig. 15. (a) Training (b) Validation (c) Testing and (d) Overall
values of Pearson coefficients
Fig. 16. Actual versus Predicted performance of ANN.
5.4 Neural network predicted results
The performance of the applied ANN model is summarized in
Table 4. From Table 4, it can be seen that ANN has an R2 of 0.98,
which represents that the prepared prediction model can explain
98% variance. RMSE and MAE readings reiterate the fact the
designed model has a very low prediction error as these readings
are calculated from the actual and predicted values. Similarly, Lin’s
shows the agreement between the actual and predicted value of
0.99 indicating the predicted results approaches to the original
values. In the end, the Pearson coefficient was obtained as 0.99
which represents that the predicted values show a strong
correlation with the actual values. It can also be observed from
Fig. 15, the correlation coefficient of training, validation, and
testing is strong with an overall correlation is 0.99.
The actual versus predicted graph is shown in Fig.
16, which indicates predicted values are very close to the actual
ones and the error between them is very low. Similarly, the boxplot
shown in Fig. 17 reiterates the fact that the residual values are
low. Residuals were evaluated by deducting the predicted values
from the actual ones.
Table 4. Performance of the ANN model
Sr. No Evaluation Measures ANN
1 MAE 9.17
2 R2 0.98
3 RMSE 14.13
4 Lin 0.99
5 R 0.99
Fig. 17. Residual of the ANN model.
5.5 Wear mechanisms
Erosive mechanisms of HVOF deposited AISI 316L steel were
investigated with the help of the SEM micrographs and the EDS
images. The materials’ properties directly contribute to the process
of silt erosion, which fundamentally contributes to the mechanism
of material deterioration. Various researchers reported that the
cutting, fracture, and cracks occur as the common mechanisms on
the surface of the centrifugal slurry pump’s components (Desale et
al., 2008; Gandhi et al., 2003, 1999; Gupta et al., 1995). The erosion
mechanisms of conventional and ceramics added WC–10Co4Cr
coatings by sand particles are shown in Fig. 18. Brittle fractures,
sharp edges, pits, and deep craters can be perceived on the SEM
image of worn conventional WC–10Co4Cr coating, as shown in
Fig. 18(a). In Fig. 18(b), deep craters and fracture initiation were
visualized in SEM images of Y2O3 ceramics added WC–10Co4Cr
coating. Conventional WC–10Co4Cr coating showed severe
erosive wear by the sand particles. For the bottom ash particles,
the conventional WC–10Co4Cr coating showed the large craters
and pitting mechanisms, as shown in Fig. 19(a). Bombarded
regions, cracks, and brittle cutting mechanisms appeared more
clearly on the surface of Y2O3 ceramics added WC–10Co4Cr
coating, as represented in Fig. 19(b). However, the narrow
ploughing, and smeared regions appeared on conventional WC–
10Co4Cr coating (Fig. 20a). In Fig. 20(b), the larger lip
formations and lip detachments appeared on the eroded surface of
Y2O3 ceramics added WC–10Co4Cr coating. The schematic
diagram of the erosion mechanism due to the addition of Y2O3
ceramics is shown in Fig. 21. SEM micrographs revealed the
ploughing, lip formations, and smears that were formed majorly in
the case of Y2O3 reinforced WC–10Co4Cr coating. The wear
mechanisms by particles at high and low impact angles are
schematically illustrated in Fig. 21(a, b). The addition of Yttrium
oxide content in WC–10Co4Cr powder contributes to the
betterment of the brittleness in the coating (El-Kady, 2013).
Furthermore, the additional Yttrium oxide content improves the
densification of the WC–10Co4Cr coating. The erosion mechanism
due to WC–10Co4Cr coating changes with the densification of
coating, as shown in Fig. 21(c, d). The intrasplat regions form
smoother which promotes the rebounding of striking particles.
Yttrium oxide has a finer particle size consequently, it
conglomerates to the matrix of WC. As a result, the void gap
existing in the WC-10Co4Cr reduces which reinforces the coating,
and erosive wear decreases (El-Kady, 2013; Nath and Kumar, 2018)
 Fig. 18. Mechanism of erosive wear of (a) conventional and (b) Y2O3 ceramics added WC-10Co4Cr coatings by sand slurry.

Fig. 19. Mechanism of erosive wear of (a) conventional and (b) Y2O3 ceramics added WC-10Co4Cr coatings by bottom ash slurry.

Fig. 20. Mechanism of erosive wear of (a) conventional and (b) Y2O3 ceramics added WC-10Co4Cr coatings by fly ash slurry.
 Fig. 21. Mechanisms of erosive wear of conventional and Y2O3 ceramics added WC-10Co4Cr coating at low and high impingement conditions.
6. CONCLUSIONS
The erosive wear behavior of conventional and Yttrium-oxide
added WC–10Co4Cr coatings were been investigated in the
present work. The effect of different parameters on erosive wear
was examined during the experiments. The following remarks are
conclusions from the present study:
 ANN model has successfully predicted the results of erosion
wear and found in a good agreement with a correlation
coefficient of 0.99.
 The addition of Y2O3 ceramics resulted in significant changes
in the properties of WC–10Co4Cr powder such as the
hardness and porosity were decreased.
 Erosive wear results reveal that the deposition of conventional
WC–10Co4Cr coating has improved the wear resistance of
AISI 306L steel by 9.98% at an impingement condition of 0°
for the increase in rotational speed.
 The wear performance of conventional WC–10Co4Cr coating
was improved by 45.9% by blending with the Yttrium-oxide
ceramics (at impingement condition of 0° for variation of
rotational speed).
 The power-law index for rotational speed (i.e. particles
velocity) was found higher as compared to concentration
(wt %). This confirms that the rotational speed was the
dominant parameter during the parallel flow impingement
conditions (0°).
 A lower tendency for material brake-outs, and the
densification and improved elongation were the key reason for
the enhanced performance of Y2O3 ceramics added WC–
10Co4Cr coating.
 Erosion wear of conventional and Y2O3 reinforced WC–
10Co4Cr coatings possess a brittle mode of failure.
 Microscopically, brittle fractures, sharp edges, pits, and deep
craters can be perceived on the SEM image of worn
conventional WC–10Co4Cr coating for the sand slurry.
However, deep craters and fracture initiation were visualized
in SEM images of Y2O3 ceramics added WC–10Co4Cr
coating.
ACKNOWLEDGMENT
The numerical data used for the ANN was collected for this
research was taken from the Ph.D. thesis of the corresponding
author. This work is an extension of the Ph.D. work of the
corresponding author.
FUNDING STATEMENT
The authors received no financial support from the
Institute/University or any funding agency or any non-
profit/profit Industry for the research, authorship, and/or
publication of this article.
CONFLICT OF INTEREST STATEMENT
The authors declare that they have no affiliations with or
involvement in any organization or entity with any financial
interest, or non-financial interest in the subject matter or materials
discussed in this manuscript.
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