Abstract
In this experimental study, chromium oxide powder was sprayed on a low-carbon steel substrate using the atmospheric plasma spray process. The current and standoff distances (SODs) were varied to study their effect on the fracture toughness of the coatings. Theoretically, as the arc current increases, the melting of the ceramic oxide should increase and this in turn should lead to the formation of a dense coating. However, it was observed that if the arc power is too high and because the particle size of the powder is small (approximately 30 μm), the particles tend to fly away from the plasma core. Similarly, an appropriate SOD should provide the particles with more melting time, thus resulting in a dense coating. On the other hand, a larger SOD leads to the solidification of the molten particles before the droplets can reach the substrate. All these effects may lead to substantial variation in the fracture toughness of the coating. The present paper attempts to correlate the plasma spraying parameters and microstructure of the coating with the fracture toughness and other primary coating properties.
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The authors are extremely grateful to Prof. Mihir Sarangi, IIT Kharagpur for providing his research facilities. Authors also acknowledge the MHRD, Govt. of India for the financial support.
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Simanchal KAR. He is a Ph.D student in the Department of Mechanical Engineering at Indian Institute of Technology Kharagpur. He received his B.Tech and M.Tech degrees in mechanical Engineering in 2006 and 2011 from KIIT University, Bhubaneswar, India.
His research interests include abrasive machining process, thermal spray processes, and material characterization.
Partha Pratim BANDYOPADHYAY. He received his M.Tech and Ph.D degrees in mechanical engineering from IIT Kharagpur, India, in 1992 and 2000, respectively. He is currently attached to IIT Kharagpur as a professor of mechanical engineering.
His research interests include CNT or diamond particulate reinforced coatings, micro and nano finishing of thermally sprayed coatings, laser treatment of coatings, etc.
Soumitra PAUL. He received his M.Tech and Ph.D degrees in mechanical engineering from IIT Kharagpur, India, in 1989 and 1994, respectively. He is attached to IIT Kharagpur as a professor of mechanical engineering. His research interests include machining, grinding, cutting tool coating, thick coating, finishability of thick coatings, high speed grinding of ceramics and carbon fibre ceramic matrix composites, high speed grinding of aerospace materials, minimum quantity lubrication in machining and grinding, micro machining, etc.
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Kar, S., Bandyopadhyay, P.P. & Paul, S. Effect of arc–current and spray distance on elastic modulus and fracture toughness of plasma-sprayed chromium oxide coatings. Friction 6, 387–394 (2018). https://doi.org/10.1007/s40544-017-0166-6
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DOI: https://doi.org/10.1007/s40544-017-0166-6