St37 Düşük Karbonlu Çeliğin Erozyon Aşınma Davranışı Üzerine Gaz Metal Ark ve Elektrot Metal Ark Kaynağı Kaplamalarının Etkisi

Abstract

Bu araştırmada, St37 düşük karbonlu çeliğe uygulanan kaynak kaplama yöntemlerinin erozif aşınma davranışı üzerindeki etkileri incelenmiştir. Malzeme yüzeyi GMAW ve EMAW sertleştirme teknikleri kullanılarak kaplanmıştır. Numunelerin Erozif aşınma özelliklerini kıyaslamak için çamur erozyonu aşınma deneyleri gerçekleştirilmiştir. Ayrıca, farklı kaplamaların erozif aşınma direnci, çeşitli çarpma hızlarında (1.5–4.5 m/s) ve açılarında (15°–45°) incelenmiştir. Taramalı elektron mikroskopu kullanılarak elde edilen aşınma mekanizmaları mikroyapısal olarak analiz edilmiştir. Deneyler sonrası numunelerin kütle kaybı ve yüzey pürüzlülüğü belirlenmiştir. Çarpma açısı, çarpma hızı ve kaplama parametrelerinin Erozif aşınma davranışına etkileri kütle kaybı, yüzey pürüzlülüğü ve mikroyapılar incelenerek değerlendirilmiştir. Bulgular, erozif aşınma sürecinde en önemli faktörün çarpma hızı olduğunu ve çarpma hızının 4.5 m/s'ye yükseldiğinde kütle kaybının en az üç katına çıktığını göstermiştir. GMAW kaplamalı numune, en zorlu koşullarda bile kütle kaybı açısından (% 28.84 daha az) kaplamasız St37'den daha iyi performans göstermiştir. Bununla birlikte, yüzey incelemelerine göre, kaplamalı numuneler yüksek enerjili darbeler altında kırılgan davranış sergilemiştir. Sonuç olarak, GMAW kaplamalı St37 numunesinin hizmet ömrü açısından en verimli çözüm olduğu belirlenmiştir.

Keywords

• Erozif aşınma
• kaynak kaplama
• GMAW
• EMAW
• regresyon analizi

Effect of gas metal arc and electrode metal arc welding coatings on erosive wear behavior of St37 plain carbon steel

Abstract

This study examined how various coating techniques affected the erosive wear behavior of St37 low-carbon steel. Surface of material was coated using GMAW and EMAW hardening techniques. To compare the erosive wear properties of the samples, slurry erosion wear experiments were conducted. Also, erosive wear resistance of different coatings was examined at various impact velocities (1.5–4.5 m/s) and angles (15°–45°). Microstructural analysis was done on the wear mechanisms discovered using scanning electron microscopy. After experiments, mass loss and surface roughness of the samples were measured after the experiments. The effects of impact angle, impact velocity, and coating parameters on erosive wear behavior were evaluated by examining mass loss, surface roughness, and microstructures. Findings showed that the most important factor in the erosive wear process is the impact velocity, and that mass loss increased at least threefold when the impact velocity was increased to 4.5 m/s. The GMAW-coated specimen outperformed the uncoated St37 in terms of mass loss (28.84% less) even under the most demanding conditions. However, according to surface inspections, the coated specimens exhibited brittle behavior under high-energy impacts. Consequently, the GMAW-coated St37 specimen was determined to be the most efficient solution in terms of service life.

Keywords

• Erosive wear
• weld coating
• GMAW
• EMAW
• regression analysis

References

1. T. Deng, Erosive Wear Mechanisms of Materials—A Review of Understanding and Progresses, Materials 18 (2025). https://doi.org/10.3390/ma18071615.
2. M.G. Petrescu, A.I. Popovici, A. Niță, D. Isbășoiu, T. Dumitru, M. Tănase, Modelling Wear Phenomena Specific to Mixer Blades in Concrete Production Plants, Applied Sciences (Switzerland) 14 (2024). https://doi.org/10.3390/app14103988.
3. C. Kang, M. Li, S. Teng, H. Liu, Z. Chen, C. Li, Erosive Wear Caused by Large Solid Particles Carried by a Flowing Liquid: A Comprehensive Review, Processes 12 (2024). https://doi.org/10.3390/pr12061150.
4. W.S. Labiapari, R.J. Gonçalves, C.M. de Alcântara, V. Pagani, J.C. Di Cunto, J.D.B. de Mello, Understanding abrasion-corrosion to improve concrete mixer drum performance: A laboratory and field approach, Wear 477 (2021). https://doi.org/10.1016/j.wear.2021.203830.
5. G. Saha, K. Valtonen, A. Saastamoinen, P. Peura, V.T. Kuokkala, Impact-abrasive and abrasive wear behavior of low carbon steels with a range of hardness-toughness properties, Wear 450–451 (2020). https://doi.org/10.1016/j.wear.2020.203263.
6. M. naser S. Far, M.M. Farsibaf, F. Kolahan, S. Elhami, Analyzing weld bead geometry and microstructure in ultrasonic-assisted activated flux TIG welding of ST37 steel, International Journal on Interactive Design and Manufacturing (2024). https://doi.org/10.1007/s12008-024-02060-1.
7. A.K. Krella, D.E. Zakrzewska, A. Marchewicz, The resistance of S235JR steel to cavitation erosion, Wear 452–453 (2020). https://doi.org/10.1016/j.wear.2020.203295.
8. Y. Göl, B. Kılınç, Effect of Boron Concentration in the Fe-Cr-Mo-(B,C) Hardfacing Alloys on the Microstructure and Mechanical Properties, J Mater Eng Perform (2024). https://doi.org/10.1007/s11665-024-10123-3.

9. V. Javaheri, D. Porter, V.T. Kuokkala, Slurry erosion of steel – Review of tests, mechanisms and materials, Wear 408–409 (2018) 248–273. https://doi.org/10.1016/j.wear.2018.05.010.
10. K. Holmberg, A. Erdemir, Influence of tribology on global energy consumption, costs and emissions, Friction 5 (2017) 263–284. https://doi.org/10.1007/s40544-017-0183-5.
11. R.H. Purba, K. Kusumoto, K. Shimizu, V. Efremenko, Erosive Wear Behavior of Novel Hybrid Multicomponent Cast Alloys with Different C and B Contents, Lubricants 11 (2023). https://doi.org/10.3390/lubricants11060243.
12. P. Verma, R. Tyagi, S. Mohan, Effect of microstructure, impact velocity and angle on erosive wear of medium carbon, dual phase and fully martensitic steels, Wear 518–519 (2023). https://doi.org/10.1016/j.wear.2023.204645.
13. Q.B. Nguyen, C.Y.H. Lim, V.B. Nguyen, Y.M. Wan, B. Nai, Y.W. Zhang, M. Gupta, Slurry erosion characteristics and erosion mechanisms of stainless steel, Tribol Int 79 (2014) 1–7. https://doi.org/10.1016/j.triboint.2014.05.014.
14. C. Katsich, E. Badisch, M. Roy, G.R. Heath, F. Franek, Erosive wear of hardfaced Fe-Cr-C alloys at elevated temperature, Wear 267 (2009) 1856–1864. https://doi.org/10.1016/j.wear.2009.03.004.
15. M. Pashechko, K. Dziedzic, P. Stukhliak, M. Barszcz, J. Borc, J. Jozwik, Wear Resistance of Eutectic Welding Coatings of Iron-Based Fe–Mn–C–B–Si–Ni–Cr at Increased Temperature, Journal of Friction and Wear 43 (2022) 90–94. https://doi.org/10.3103/S106836662201010X.
16. B. Benli, I. Celik, Surface Modification and Analysis of St37 Steel with Al2O3-TiO2, ZrO2, and Cr2O3 Ceramic Coatings: Structural, Mechanical, and Tribological Properties, Tribol Int 191 (2024). https://doi.org/10.1016/j.triboint.2023.109183.
17. D.C. Ribu, R. Rajesh, D. Thirumalaikumarasamy, A.R. Kaladgi, C.A. Saleel, K.S. Nisar, S. Shaik, A. Afzal, Experimental investigation of erosion corrosion performance and slurry erosion mechanism of HVOF sprayed WC-10Co coatings using design of experiment approach, Journal of Materials Research and Technology 18 (2022) 293–314. https://doi.org/10.1016/j.jmrt.2022.01.134.
18. Y. Korobov, M. Antonov, V. Astafiev, I. Brodova, V. Kutaev, S. Estemirova, M. Devyatyarov, A. Okulov, Erosion Wear Behavior of HVAF-Sprayed WC/Cr3C2-Based Cermet and Martensitic Stainless Steel Coatings on AlSi7Mg0.3 Alloy: A Comparative Study, Journal of Manufacturing and Materials Processing 8 (2024). https://doi.org/10.3390/jmmp8050231.
19. Z.B. Zheng, Y.G. Zheng, W.H. Sun, J.Q. Wang, Erosion-corrosion of HVOF-sprayed Fe-based amorphous metallic coating under impingement by a sand-containing NaCl solution, Corros Sci 76 (2013) 337–347. https://doi.org/10.1016/j.corsci.2013.07.006.
20. A.R. Pradhan, S. Kumar, C. Gupta, S.K. Mandal, Erosion wear performance of HVOF sprayed WC-10Co-4Cr + 2% TiO2 coating on SS-409 using slurry jet erosion tester, Results in Surfaces and Interfaces 16 (2024). https://doi.org/10.1016/j.rsurfi.2024.100277.
21. M. Akhondizadeh, N. Afkhami, Determination of erosion equation factors of AISI1020 by experimental data, Mechanics and Industry 21 (2020). https://doi.org/10.1051/meca/2019087.
22. R. Demirsöz, M.E. Korkmaz, M.K. Gupta, A.G. Collado, G.M. Krolczyk, Erosion characteristics on surface texture of additively manufactured AlSi10Mg alloy in SiO2 quartz added slurry environment, Rapid Prototyp J 28 (2021) 916–932. https://doi.org/10.1108/RPJ-10-2021-0283.
23. O. Çakır, R. Demirsöz, M.T. Özdemir, M.E. Korkmaz, M.K. Gupta, M. Günay, N.S. Ross, A. Nag, Investigating the erosive wear characteristics of AISI 420 martensitic stainless steel after surface hardening by boriding, Journal of Materials Research and Technology 33 (2024) 2292–2302. https://doi.org/10.1016/j.jmrt.2024.09.208.
24. R.H. Myers, D.C. Montgomery, G.G. Vining, T.J. Robinson, Generalized linear models: with applications in engineering and the sciences, John Wiley & Sons, 2012.
25. P.P. Shitole, S.H. Gawande, G.R. Desale, B.D. Nandre, Effect of Impacting Particle Kinetic Energy on Slurry Erosion Wear, J Bio Tribocorros 1 (2015). https://doi.org/10.1007/s40735-015-0028-6.
26. P.C. Okonkwo, M.H. Sliem, M.H. Sk, R.A. Shakoor, A.M.A. Mohamed, A.M. Abdullah, R. Kahraman, Erosion behavior of API X120 steel: Effect of particle speed and impact angle, Coatings 8 (2018). https://doi.org/10.3390/COATINGS8100343.
27. M.S. Gul, R. Demirsöz, S. Kabave Kilincarslan, R. Polat, M.H. Cetin, Effect of Impact Angle and Speed, and Weight Abrasive Concentration on AISI 1015 and 304 Steel Exposed to Erosive Wear, J Mater Eng Perform (2024). https://doi.org/10.1007/s11665-023-09117-4.
28. D. López, J.P. Congote, J.R. Cano, A. Toro, A.P. Tschiptschin, Effect of particle velocity and impact angle on the corrosion-erosion of AISI 304 and AISI 420 stainless steels, in: Wear, 2005: pp. 118–124. https://doi.org/10.1016/j.wear.2005.02.032.
29. V.A. Mainardi, R.P. Cardoso, S.F. Brunatto, C.J. Scheuer, Slurry and liquid impingement erosion behavior of low-temperature plasma carburized AISI 420 martensitic stainless steel, Surf Coat Technol 477 (2024). https://doi.org/10.1016/j.surfcoat.2024.130390.
30. Y. Reda, A. Gamal, R. Abdel-Karim, S.M. El-Raghy, Erosion–Corrosion Behaviour of ASTM A106 GR.B Carbon Steel Pipelines, J Bio Tribocorros 9 (2023). https://doi.org/10.1007/s40735-022-00729-2.
31. C. Wang, M. Liu, H. Wang, G. Jin, G. Ma, J. Zhang, S. Chen, Tribological properties and solid particle erosion wear behavior of Al2O3-13 wt%TiO2/Al2O3-PF composite coatings prepared on resin matrix by supersonic plasma spraying, Ceram Int 50 (2024) 29987–29996. https://doi.org/10.1016/j.ceramint.2024.05.294.