Session: 03-20-03: Manufacturing: General

Paper Number: 145468

145468 - Manufacturing of a Cemented Carbide Coated Component on Design for Manufacturing Toward Combined Impact and Wear Resistance 

Manufacturing of coated components with hard, wear-resistant coatings to operate under impact service condition is a challenge of high-performance demand for mechanical equipment in industrial sectors. A new strategy of design for manufacturing with integrated design and processing was developed in our recent work considering processing effect on final performance via the pivot role of surface integrity. On this knowledge-based strategy, the manufacturing process optimization of WC-Ni cemented carbide coated components was studied for implementing a two-layer coating design toward the desired performance of combined impact and wear resistance. The two-layer coating design comprised of a hard WC-Ni outer layer, and an interlayer of Ni-based alloy onto a steel substrate, with a flat-on-cylinder contact impacting configuration in service condition. In the design phase, numerical analysis of impact stress and strain field evolution was carried out comparatively for the two-layer coating and the conventional single-layer coating design under an impact load of 10-kN order. It was revealed that, the high stresses localized on the coating surface and interfaces under the impacts may cause the surface integrity changes of coated components, including surface crater formation upon plastic deformation as well as crack formation both in coating and at coating-substrate interface; and introducing the interlayer with intermediate elastic modulus and hardness in between the steel substrate and the outer layer, as well as in an appropriate thickness, can mitigate the surface integrity changes to failure of coated components. The manufacturing processes were accordingly optimized with the two-layer design by employing high velocity oxy-fuel spraying and/or high frequency induction cladding technologies. In good agreement with the numerical analysis, the two-layer coating prepared by the thermal spray process showed a better impact resistance over the single-layer coating, leading to less plastic deformation, surface and/or interface cracking of the coated component, while a further improvement was achieved by synergistically optimized induction cladding process for the interlayer to strengthen the interface with a stronger metallurgical bonding between the interlayer and the steel substrate.

Presenting Author: x.p. Zhu Dalian University of Technology

Presenting Author Biography: XiaoPeng ZHU received the Ph.D. degree in plasma physics from Dalian University of Technology, China, in 2003, was working as postdoc in Nagaoka University of Technology, Japan, 2003-2006. He is currently working at the School of Material Science and Engineering, Dalian University of Technology, China. His research interests include surface engineering, high-performance manufacturing and performance evaluation.

Authors:

x.p. Zhu Dalian University of Technology
g.j. Wu Dalian University of Technology
s.j. Zhang Dalian University of Technology
z.h. Shang Dalian University of Technology
M. K. Lei Dalian University of Technology