Experimental analysis and optimization of plasma spray parameters on microhardness and wear loss of Mo-Ni-Cr coated super duplex stainless steel

ABSTRACT

Plasma spray coatings are one among the economic path to offer quick solutions for preventing the part (substrate) failures due to rapid wear. In the present work, Mo-Ni-Cr powder is used as a coating material on super duplex stainless steel to minimise the wear loss. The microhardness of the coating is affected by the factors (current, powder feed rate and standoff distance) of the plasma spray coating process. Taguchi method is followed for preliminary experimental plan, analysis, and to perform optimisation for maximum microhardness. The results showed that the current being the dominant effect followed by powder feed rate and standoff distance on the microhardness of coated samples. The optimised plasma spray condition resulted in the highest coating microhardness (i.e., 764.33 HV), which is 2.78 times higher than that of super duplex stainless steel (i.e., 275 HV). Taguchi experiments are conducted to know the factors (load, sliding speed and sliding distance) influence the wear loss of coated samples prepared for optimised plasma spray conditions. The applied load and sliding speed are found statistically significant, whereas the sliding distance is insignificant towards wear loss. The results of wear loss of the substrate (uncoated sample) and optimised condition of the coated sample are found equal to 18 mg, and 2.8 mg, respectively.

KEYWORDS:

• Plasma spray coating
• wear
• Taguchi
• microhardness
• super duplex stainless steel

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Notes on contributors

Manjunath Patel G C

Manjunath Patel G C received his B. E. in Mechanical Engineering from Jawaharlal Nehru National College of Engineering, Shivamogga, India and M. Tech. in Production Management from KLS Gogte Institute of Technology, Belagavi, India in 2009 and 2011, respectively. He received his Ph. D in Mechanical Engineering from National Institute of Technology Karnataka, Surathkal, India in 2015. He is working at present as Asst. Professor in the Department of Mechanical Engineering of PES Institute of Technology and Management, Shivamogga, India. His research interests include modelling and simulation of mechanical systems, statistical and soft computing tools. He has published around 40 publications in various International Journals, 16 articles in International/National Conferences, 1 book and 6 book chapters. ORCID ID: http://orcid.org/0000-0001-9340-7464

Pradeep N B

Pradeep N B received his B. E. in Mechanical Engineering from Jawaharlal Nehru National College of Engineering, Shivamogga, India and M. Tech. in Production Engineering systems technology from UBDT College of Engineering, Davangere India in 2009 and 2011, respectively. Undergoing Research work in the field of Nano metallurgy. He is working at present as Asst. Professor in the Department of Mechanical Engineering of Jawaharlal Nehru National College of Engineering, Shivamogga, India. His research interests include Material science, Metallurgy statistical and soft computing tools. He has published around 2 publications in various International Journals, 4 International conference papers and Organized two National level FDP.

Girisha L

Girisha L, obtained his Bachelor of Engineering degree in Mechanical Engineering from Bapuji Institute of Engineering and Technology, Davanagere, Karnataka, affiliated to Kuvempu University, Shivamogga, Karnataka, India in the year 2002 and Master of Technology in Machine Design from Bapuji Institute of Engineering and Technology, Davanagere, Karnataka, affiliated to Visvesvaraya Technological University, Belagavi, Karnataka, India in 2004. He received his Ph. D in Mechanical Engineering Science from Visvesvaraya Technological University, Belagavi, Karnataka, India in the year 2016. Presently he is working as Associate Professor in the Department of Mechanical Engineering of PES Institute of Technology and Management, Shivamogga, India. His research interests include Nanocomposites, Nanomaterials and its characteristics, Damping and Tribological behaviour, Medical and Dental Materials. He has published around 20 publications in various International Journals.

Harsha H M

Harsha H M received his B. E. in Mechanical Engineering from Sri Jagadguru Murugarajendra Institute of Technology, Chitradurga, India in 2000 and M. Tech. in Design Engineering, K.L.E. Society’s College of Engineering & Technology, Belagavi, India in 2004. He is now working as Assistant Professor in the Department of Mechanical Engineering of GM Institute of Technology, Davangere, India. He has 16 years of Teaching Experience. His research interests include Composites and Fracture Mechanics. He has published 3 technical papers and 1 review article in International Journals.

Arun Kumar Shettigar

Dr. Arun Kumar Shettigar obtained Bachelor Degree in Mechanical Engineering from NMAMIT Nitte, Karnataka, Post-graduation in Mechatronics Engineering from NITK, India, and Doctoral Degree in Mechanical Engineering with specialization in Manufacturing Engineering from NITK India. He has over 1 year of industrial experience in the field of design, 5 years of teaching and 5 years of research experiences. Presently he is working as an Assistant Professor in the Mechanical Engineering Department of National Institute of Technology Karnataka. His areas of interests are solid-state welding process, micromachining, application of artificial intelligent in manufacturing/machining process, advanced manufacturing process, CAD/CAM and metal matrix composite materials.