Improving WC-Co coating adhesive strength on rough substrate: Finite element modeling and experiment

doi:10.1016/j.jmst.2019.07.033

Abstract

Abstract:

The adhesive strength in a coating-substrate system is of primary importance for the coating lifetime in service. However, the underlying mechanism is not fully understood due to the complex internal structure of composite coatings. In this study, the effect of substrate roughness on the adhesive strength of WC-Co coatings was investigated by experiment and simulation. Results show that the adhesive strength is significantly affected by the roughness. In the case of the Ra<2 μm, the adhesive strength is approximately 35-46 MPa. When the Ra is 4 μm, the adhesive strength increases to nearly 60 MPa. A finite element model was developed to correlate the roughness with adhesive strength. It is found that the predicted values are well consistent with the experimental data. In addition, with the increase of the roughness, the residual stress would be changed from concentrated state to widespread state, which decreases the critical stress to result in crack propagation. That’s why a larger roughness can cause a higher adhesive strength. This study gives understanding on the mechanism of adhesive strength affected by roughness, which contributes to the parameter optimization with better performance.

Key words: Adhesive strength, Roughness, Lifetime, Simulation, XFEM, Residual stress

Adnan Tahir, Guang-Rong Li, Mei-Jun Liu, Guan-Jun Yang, Cheng-Xin Li, Yu-Yue Wang, Chang-Jiu Li. Improving WC-Co coating adhesive strength on rough substrate: Finite element modeling and experiment[J]. J. Mater. Sci. Technol., 2020, 37: 1-8.

Figures/Tables 11

Fig. 1. Model applied for finite element calculations: (a) dimensional and geometric parameters, (b) traction separation failure criterion for the uniaxial case, (c) focused part of the FE mesh and modelling of crack growth.

Table 1 Mechanical properties of the materials applied for the microscopic and macroscopic modelling [[25],[33],[34],[37]].

Material	Elastic modulus (GPa)	Poison’s ratio	Initiation stress (GPa)	Fracture energy (J/m²)
WC	700	0.24
Co	227	0.30	0.3	18
WC-Co	600	0.22
Steel	200	0.2

Fig. 2. Morphology of WC-12Co cermet powder: (a) surface morphology, (b) ross-sectional microstructure.

Table 2 Spraying parameters of HVOF.

Parameters	Plasma spraying
Pressure of oxygen (MPa)	0.7
Flow rate of oxygen (m³/h)	13
Pressure of C₃H₈ (MPa)	0.4
Flow rate of C₃H₈ (m³/h)	1.3
Pressure of N₂ (MPa)	0.5
Flow rate of N₂ (L/h)	1500
Spray distance (mm)	180

Fig. 3. Typical SEM images of WC-12Co coating: (a) low magnification, (b) high magnification corresponding to the black box.

Fig. 4. Typical laser-optical microscopy in 3D of substrate sandblasted by grit in 750?μm, 250?μm and 50?μm: (a1) sandblasted by 750?μm, (a2) high magnification of (a1), (b1) sandblasted by 250?μm grit, (b2) high magnification of (b1), (c1) sandblasted by 50?μm grit, (c2) high magnification of (c1).

Fig. 5. Effect of grit size on the roughness of substrate.

Fig. 6. Adhesive strength as a function of roughness.

Fig. 7. Evolution of residual stress of S22 at same time just before crack starts with different Ra values.

Fig. 8. Stress vs displacement: (a) All steel/WC-Co models, (b) expanded values for all models greater than Ra of 0.5?μm.

Fig. 9. Adhesive strength of experimental and simulation values as a function of roughness.

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