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Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings


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Electrochemical corrosion and erosive wear behaviour of microwave


processed WC-10Co4Cr clad on SS-316
Paramjit Singh, Deepak Kumar Goyal, Amit Bansal ⇑
Department of Mechanical Engineering, Inder Kumar Gujral Punjab Technical University, Kapurthala, India

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

Article history: WC-10Co4Cr cladding over an austenitic stainless steel (SS-316) was fabricated by using a cost- effective
Received 31 August 2021 microwave technique. Cladding was performed with 1.20 kW power and a frequency of 2.45 GHz in an
Received in revised form 9 September 2021 industrial microwave oven. The XRD surveillance reveals a cluster of carbide phases adjunct to W-Cr-
Accepted 14 September 2021
Fe based hexagonal matrix. The SEM examination reveals a solid microstructure and a homogeneous
Available online xxxx
reinforced skeleton with porosity measures of less than 1% in the clad specimen. Tungsten (W) dis-
tributed equally in matrix and carbides, resulting in bulk hardness and matrix micro hardness increasing
Keywords:
gradually and reaching a peak at 750HV, respectively, which is significantly greater than the base metal
SS-316
Cladding
(SS-316) hardness (about 220HV). The clads erosive wear was measured at various impact angles (30°,
Microwave 60°, and 90°) by utilizing a solid particle erosion with alumina as the erodent. In addition, corrosion test-
Surface ing found that in the NaCl solution of 3.5 wt% the cladded specimen exhibited the less corrosion resis-
Erosion tance than that of the base metal.
Corrosion Copyright Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Con-
ference on Functional Material, Manufacturing and Performances

1. Introduction cial benefits such as consistently heated, volumetric heating, better


mechanical qualities and microstructural characteristics, micro-
A critical challenge in tribological evolution persisted in requir- wave heating/ processing of materials is gaining popularity [12].
ing novel materials for usage in serially harsh conditions. Facet Microwave material processing causes thermal energy to be
deterioration occurs in engineering components used in aerospace, reduced on the atomic level in the material and improves produc-
power, and petrochemical industries, primarily due to erosion and tivity. The volumetric temperature generated in the material by the
corrosion. Surface engineering is the way most typically used to atomic level interaction in microwave is a unique phenomenon
improve the quality and function of the surface of a material with- which is different from the conductive mode of heat transfer in
out changing the inside prevailing properties [1]. The erosion and the conventional surface heating technique. This unique phe-
corrosion resistance for ferrous alloys in oil and gas industries nomenon reduces material thermal gradients and reduces the
(stainless steel, mild steel) are an important topic of research. residual stresses inside the microwave processed materials
The surface properties of ferrous alloys can alter with example like [13,14]. Sharma et al., [15] structured a microwave heating patent
thermal treatment, PVDs, thermal spurts, epoxy coats, enamel in the form of a microwave cladding for improving metal material
coatings, laser cladding and microwave cladding [2–7]. Metallic functionality. The authors used microwave heating (MH) approach
powder coating and cladding provide exceptional resistance to moralities to improve the tribological and mechanical capabilities
mechanical shocks, particularly in applications involving severe of microwave clads. Austenitic stainless steel (SS-316) is the most
erosive wear and chemical corrosion. Furthermore, slit initiation common material that combines good mechanical qualities,
tendency during the cladding process’s brisk melt pool and solidi- including erosion and resistance to corrosion. It is widely known
fication phase [8–12] and at these slit origin locations; corrosion as ’marine grade stainless steel’ but is not resistant to warm
(through fissures and pits) is frequently invented. Due to their spe- waters. Surface corrosion is noticeable as brown discoloration in
maritime conditions (SS-316), which is often associated with
fissures and a rough surface finish. The SS-3160 s outstanding
⇑ Corresponding author. mechanical qualities ensure that the solid solution offered by the
E-mail address: amit.bansal978@gmail.com (A. Bansal).

https://doi.org/10.1016/j.matpr.2021.09.241
2214-7853/Copyright Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Functional Material, Manufacturing and Performances

Please cite this article as: P. Singh, D. Kumar Goyal and A. Bansal, Electrochemical corrosion and erosive wear behaviour of microwave processed WC-
10Co4Cr clad on SS-316, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2021.09.241
P. Singh, D. Kumar Goyal and A. Bansal Materials Today: Proceedings xxx (xxxx) xxx

WC-10Co4Cr based clads is hardened. The erosive wear resistance employed for successful fabrication of clad on the SS-316 substrate
of WC–Co based materials is said to be dependent on numerous is shown in Table 2.
aspects such as carbide particle size distribution, carbide phase Fig. 2 shows the design of the experimental device used to fab-
hardness, and carbide volume percentage. The addition of the Cr ricate the clad specimen using an economical microwave method.
matrix provides an excellent resistance to corrosion in an oxidising Clad particles have been efficiently deposited on the surface of the
environment, by forming a passive, oxide-placed structure on the substrate employing Microwave hybrid heating (MHH) technolo-
SS-316 surface, which protects the material against foster corro- gies. As shown in Eq. (2), the susceptor powders (charcoal) have
sion, with a highly hard tungsten (W) matrix, resulting in low sur- a large loss tangent value during microwave exposure, and transfer
face erosion of the steel substrate [15–19]. Microwave cladded the heat to the clad powder through the conductivity mode
WC-10Co4Cr on stainless steel (SS-316) has never been docu- through the alumina plate (separator). The microwaving radiation
mented for erosive wear and corrosion. In this study, the surface absorbed at room temperature can be explained on the basis of loss
characteristics of stainless steel were thus improved by the use tangent tand. The tand can be explained as ratio of e to e. where e0 is
of the MH method based microwave cladding. In addition, a num- permittivity, the loss factor that indicates microwave penetration
ber of microstructural, mechanical and corrosion tests were used into the material, e is the capacity of the substance to store energy,
to characterise the clad specimens. and tan d is the tangent of loss, i.e. it indicates the ability of mate-
rial to convert the store energy into heat energy.

1.1. Material & method


2. Characterization tool
Due to its excellent hardness and corrosion resistance, the com-
mercially available WC-10CO4Cr powder was utilized as clad pow- The clad specimen was sliced perpendicular to the clad direc-
der. A typical SEM micrograph showing the WC-10Co4Cr powder tion by with a low speed diamond saw (make: Chennai Metco,
morphology along with its EDS spectrum is shown in Fig. 1. The model: BAINCUT LSS). The mounted specimens were ground and
powder with a 40 ± 5 m diameter distribution, have a notably polished down to 2000 grit with emery sheets, then polished with
spherical shape. The base material was stainless steel (SS- 316), 1 mm diamond paste on the canvas. A SEM/EDS (model: Gemini
which is one of the most frequently used engineering materials, Ultra Plus) was used to do microstructural characterization and
and was 20  20  5 mm in size. The chemicals compositions the elemental analysis of the WC-10CO4Cr clads. At 50 g load
(wt. %) of the substrate (SS-316) and the powder WC-10Co4Cr as and 10 s dwell time, the micro hardness of the WC-10CO4Cr clads
measured by using optical emission spectrometer (OES) are pre- was evaluated using a Vickers’ micro hardness tester (make: Chen-
sented in Table 1. nai Metco, model: Economet VH1 MD). Starting from the acme of
Before clad deposition, the SS-316 substrate was ultrasonically the clad and working towards the substrate, indentations were
cleaned in an ethanol bath. The WC-10CO4Cr clad powders have made with every 100 mm.
been warmed to remove all potential moisture in a silting oven
for 8 h at 120 °C. The clad powder was manually applied to the
substrate with an average thickness of around 1 mm. In a multi- 3. Results and discussion
mode industrial microwave, the prepared clad powder was melted
on the SS-316 substrate. Other sources [15,16] provide a more 3.1. Microstructural analysis
accurate picture of the microwave cladding process. The clad pow-
ders were evenly spread on the top surface of the substrate with an The tribological properties of the clad specimens strongly
average thickness of around 1 mm. On the top of the pre-placed related to the microstructure developed in the clad region. The
powder was maintained an alumina plate (separator) with a thick- 1 mm thick microwave-induced clad exhibits has excellent metal-
ness of about 0.5 mm, and expedited powder (charcoal) susceptor lurgical bonding with the substrate. To analyse microstructural
was placed on the alumina. Then, a microwave oven chamber was characteristics, scanning electron microscope (SEM) was used to
installed and electromagnetic microwave radiation was exposed to examine the typical back scattered electron (BSE) images captured
this entire unit. A series of experiments have revealed the appro- along the cross sectional of the polished clad specimens as shown
priate process parameters. The various processing parameters in Fig. 3. The presence of tungsten carbide (W2C) and free tungsten

Fig. 1. (a) SEM image of clad powder, (d) EDS corresponding to point 1 of Fig. 1a.

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P. Singh, D. Kumar Goyal and A. Bansal Materials Today: Proceedings xxx (xxxx) xxx

Table 1
Chemical composition (wt.%) of SS 316 and clad powder.

Material Cr Co W Ni Mn C Fe Mo Si
(SS-316) 17.8 – – 13.8 2.1 0.08 72 2.9 0.023
WC-10CO4Cr powder 4.28 11.62 65.67 – – 8.43 – – –

Table 2 bution of the elements like W and C seems to be uniform as shown


Microwave processing parameters utilized for performing cladding. in Fig. 3. W and C were found to be the most prevalent elements at
Parameters Values Units metallic carbides with Fe, Co, and Cr making up the binder matrix.
Powder size 40 ± 5 mm
Powder pre heat temperature 120 °C 3.2. Erosive wear analysis
Microwave power 1.2 KW
Frequency 2.45 GHz
Time of exposure 600 Sec. The erosive wear behaviour of the microwave clad WC-10Co4Cr
was evaluated using an air jet erosion (AJE) test apparatus of solid
particulate erosion (make: Ducom, model: TR). The erosive wear
test was carried out at three different impact angles (30°, 60°,
in the indicates that the successful development of cladding using
and 90°), as shown in Fig. 4. The cumulative weight loss and ero-
microwave energy.
sion rate has been calculated using the mean value of weight loss
Alloying elements in the substrate and WC-10CO4Cr powder
per unit erosion (mg/min.) of the unclad and WC-10CO4Cr covered
particles were equally dispersed along the clad region, indicating
specimen illustrated in Table 3 observations. The erosion coeffi-
that the substrate and clad elements were completely diluted. Dur-
cient was identified as part of the volume loss ratio between the
ing microwave heating, it is noticed that probable breakdown of
specimen and the erodent discharge rate as mentioned in Table 4.
WC form beginning powder into free W & W2C occurs at high tem-
At a 30° impingement angle, weight loss (0.052) in plain SS-316 is
peratures, as shown in Eqs. (2) & (3).
clearly more than weight loss (0.002) in WC-10Co4Cr cladded
specimens. Less erosion is caused by the wear resistance and high
WC þ W ! W2 C ð2Þ hardness of the WC-10C04Cr cladded surface. The magnitude of
This free carbon may react to CO by atmospheric oxygen, which the erosion coefficient, determined from cumulative weight loss,
then escapes during solidification and results to a free cladding and is 8.6775x10-3, which is likewise higher at a 30° impingement
decreased porosity. Further reactions with cobalt binders and angle in un-cladded specimen, as shown in Fig. 4.
tungsten free (W) to generate complex carbides are residual free From Fig. 5, it is clear that the substrates are subjected to more
carbon. Metal carbides are produced in combination with powder erosive wear at all impact angles (30°, 60°, & 90°) than the clad
and substrate such as Co2, Cr2C6, and Co3W9C4, as shown in Eq. specimen used in the present investigations. The base metal was
(3) & (4). eroded through mainly micro-cutting matrix. Whereas the clad
specimen was eroded through fragmentation of hard particles, car-
bide pull outs, embedded lip formation and micro-cutting of the
9W þ 3CO þ 4C ! CO3W9C4 ð3Þ
particles. Particles of the incident stream have an impact like some
of these effects can arise when one particular particle collides with
another, such as fragmentation and embedding. The cladding
6Fe ðSubstrateÞ þ 6W þ C ! Fe6 W6 C ð4Þ
shows better erosive defiance at an impact angle of 60° & 90° com-
WC10CO4Cr microstructure covered, similar to that of the pared with 30°, which is related to the pinning and shielding effect
enhanced skeleton-structured composite, as shown in Fig. 3 i.e. of the alumina particle. The major erosion wear mechanisms of
increase in the metal matrix of W& Fe binary carbides. The distri- WC-10Co4Cr cladding were micro-cutting, micro-ploughing, splat

Fig. 2. Microwave oven cavity.

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P. Singh, D. Kumar Goyal and A. Bansal Materials Today: Proceedings xxx (xxxx) xxx

Fig. 3. Typical BSE images along the cross-sectional thickness of WC10CO4Cr clad specimen.

Fig. 4. Specimens after conducting erosive wear tests at 30°, 60°, & 90° impingement angles: (1–3) SS-316, (4–6) clad specimens.

Table 3
Cumulative weight loss calculations from observed values.

Material Impact Weight (gm’s.) change/loss after 05 min


angle (deg)
Initial weight 5 min 10 min 15 min 20 min 25 min 30 min Final weight Weight loss
SS-316 30 19.183 19.148 19.130 19.149 19.134 19.131 19.131 19.131 0.052
60 24.495 24.502 24.503 24.497 24.494 24.493 24.493 24.493 0.002
90 24.134 24.135 24.134 24.128 24.133 24.132 24.132 24.132 0.002
SS-316 (WC-10CO4Cr cladded) 30 17.475 17.477 17.475 17.473 17.474 17.473 17.473 17.473 0.002
60 21.359 21.361 21.350 21.359 21.358 21.357 21.357 21.357 0.002
90 21.535 21.537 21.536 21.535 21.534 21.533 21.533 21.533 0.002

Table 4
Calculation for cumulative volume loss and average erosion value.

Calculation’s for measuring Average erosion value


Material Impact Initial Final wt. Weight Volume loss=Wt. loss / Volume loss Erodent consumed=Feed rate  time Avg. erosion
angle wt. (mg.) (mg.) loss (mg.) Density of specimen material Erodent consumed=2.530 value (mm3/gm)
(deg)
SS-316 30 0.019183 0.019131 0.000052 0.000052 / 0.00799 0.006508135 75 gm 8.67751  103
60 0.024495 0.024493 0.000002 0.000002 / 0.00799 0.000250313 75 gm 3.33751  106
90 0.024134 0.024132 0.000002 0.000002 / 0.00799 0.000250313 75 gm 3.33751 106
Clad 30 0.017475 0.017473 0.000002 0.000002 / 0.00799 0.000250313 75 gm 3.33751  106
60 0.021359 0.021357 0.000002 0.000002 / 0.00799 0.000250313 75 gm 3.33751  106
90 0.021535 0.021533 0.000002 0.000002 / 0.00799 0.000250313 75 gm 3.33751  106

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P. Singh, D. Kumar Goyal and A. Bansal Materials Today: Proceedings xxx (xxxx) xxx

Fig. 5. BSE images of erosion impressions (1–3) plain SS-316 specimen & (4–6) WC10Co4Cr clad specimen.

Table 5 sion. Dominance of tungsten particles as shown in Fig. 3 due to for-


Potentiostat readings for corrosion rate of WC-10Co4Cr cladded specimen and SS-316. mation of metallic carbides reacted with sodium chloride result in
Corrosion parameters Ecorr Icorr Corrosion rate tungsten particles and metallic carbides pull-out from cladded
region and hence pits and cavities formed. Formed cavities in
Clad specimen 638.0 mV 32.60mA 19.07 mpy
Substrate material 592.0 mV 18.90mA 11.02mpy cladded area is rich in iron (Fe) particles leads to formation of num-
bered electrochemical cells resulting in more corrosion when
exposure to aqueous solutions. The corrosion parameters like cor-
removal and detachment of hard carbide particles as reported by rosion rate, corrosion current density, and corrosion potential of
earlier study also [20]. Further, the subsurface damage as a result WC-10Co4Cr cladded specimen and base metal SS-316 is shown
of many strikes is another key effect. To assess meaningful erosion in Table 5.
rates, numerous particle erosion exposures are clearly required. It is observed from Table 5 corrosion rate of WC-10Co4Cr
cladded specimen is 19.07 mills per year (mpy) and for steel it is
11.02 mpy. So corrosion rate and corrosion density of un-cladded
3.3. Electro-chemical corrosion analysis specimen is less than that of the WC-10Co4Cr cladded specimen.
Hence cladding of WC-10Co4Cr metallic powder has no benefit in
The corrosion potential, corrosion current, and corrosion rate improving the corrosion resistance of the austenitic stainless steel
are the important parameters used for determining the corrosion SS-316.
behaviour of the specimen. The corrosion current density (Icorr)
parameter is important for the corrosion rate calculation. The 3.4. Microhardness analysis
interaction between the metal substrate (SS-316), the covered
WC-10Co4Cr specimen, and an electrolyte solution causes electro- A Vickers microhardness tester for the un-cladded and WC-
chemical corrosion i.e. once the electrolyte entered the SS-316 10Co4Cr coated sample of 50 g of load, 0,025Kgf of force and 10 s
specimen via micro and macro-cracks, galvanic pair was developed dwell time (model: Economet VH1 MD) was used to measure the
among the cladding and the SS-316 specimen, resulting in the microhardness. Indentations made at 100 mm intervals starting
accelerated corrosion and finally leading to the degradation of from the top of the substrate and progressing to the clad. Micro-
the cladding. The results agree with earlier findings also [21]. A hardness values of WC-10Co4Cr clad from substrate to clad region
thin film of humidity on a metal surface is an electrolyte for corro- may vary. Less value of micro hardness is due to the metallic

Fig. 6. Plain (SS-316) vs. WC-10Co4Cr clad specimen hardness comparison.

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P. Singh, D. Kumar Goyal and A. Bansal Materials Today: Proceedings xxx (xxxx) xxx

matrix of tough metals like (Co & Fe). As the authors have mea- Acknowledgement
sured the microhardness from substrate region to clad region size
of indents changes from large to small is an indication of hardness The author would like to evince gratefulness to Science and
variation and corresponding values of hardness can have assessed. Engineering Research Board (SERB), India for financing this work
Microhardness of WC-10Co4Cr cladded region in more than the with project no. SRG/2019/001182.
substrate SS-316 region because of uniform distributed particles
of substrate and clad as depicts in Fig. 3(1 & 2). Presence of metallic References
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Declaration of Competing Interest https://doi.org/10.1108/WJE-10-2020-0476.
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cial interests or personal relationships that could have appeared org/10.1007/s11668-020-01057-8.
to influence the work reported in this paper.

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