Vol. 26 No. 2 2024 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru Journal “Obrabotka Metallov – Metal Working and Material Science” is indexed in the world's largest abstracting bibliographic and scientometric databases Web of Science and Scopus. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases.
OBRABOTKAMETALLOV Vol. 26 No. 2 2024 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Aff airs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, V.P. Larionov Institute of the Physical-Technical Problems of the North of the Siberian Branch of the RAS, Yakutsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 26 No. 2 2024 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Gaikwad V., Chinchanikar S. Investigations on ultrasonic vibration-assisted friction stir welded AA7075 joints: Mechanical properties and fracture analysis........................................................................................................................ 6 Sirota V.V., Zaitsev S.V., Limarenko M.V., Prokhorenkov D.S., Lebedev M.S., Churikov A.S., Dan'shin A.L. Preparation of coatings with high infrared emissivity.......................................................................................................... 23 Babaev A.S., Kozlov V.N., Semenov A.R., Shevchuk A.S., Ovcharenko V.A., Sudarev E.A. Investigation of cutting forces and machinability during milling of corrosion-resistant powder steel produced by laser metal deposition............. 38 Dolgova S.V., Malikov A.G., Golyshev A.A., Nikulina A.A. The eff ect of laser surfacing modes on the geometrical characteristics of the single laser tracks............................................................................................................................... 57 Karlina Y.I., Kononenko R.V., Popov M.A., Deryugin F.F., Byankin V.E. Assessment of welding engineering properties of basic type electrode coatings of diff erent electrode manufacturers for welding of pipe parts and assemblies of heat exchange surfaces of boiler units............................................................................................................................. 71 Yanpolskiy V.V., Ivanova M.V., Nasonova A.A., Yanyushkin A.S. Determination of the rate of electrochemical dissolution of U10A steel under ECM conditions with a stationary cathode-tool............................................................... 95 EQUIPMENT. INSTRUMENTS Zakovorotny V.L., Gvindjiliya V.E. The study of vibration disturbance mapping in the geometry of the surface formed by turning............................................................................................................................................................................. 107 Gasanov B.G., Konko N.A., Baev S.S. Study of the kinetics of forming of spherical sliding bearing parts made of corrosion-resistant steels by die forging of porous blanks............................................................................................... 127 Gvindjiliya V.E., Fominov E.V., Moiseev D.V., Gamaleeva E.I. Infl uence of dynamic characteristics of the turning process on the workpiece surface roughness........................................................................................................................ 143 Lobanov D.V., Skeeba V.Yu., Golyushov I.S., Smirnov V.M., Zverev E.A. Design simulation of modular abrasive tool........................................................................................................................................................................................ 158 MATERIAL SCIENCE EroshenkoA.Yu., Legostaeva E.V., Glukhov I.A., Uvarkin P.V., TolmachevA.I., Sharkeev Yu.P. Thermal stability of extruded Mg-Y-Nd alloy structure.................................................................................................................................. 174 Bazaleeva K.O., Safarova D.E., Ponkratova Yu.Yu., Lugovoi M.E., Tsvetkova E.V., Alekseev A.V., Zhelezni M.V., Logachev I.A., Baskov F.A. The infl uence of technological parameters of the laser engineered net shaping process on the quality of the formed object from titanium alloy VT23......................................................... 186 Efi movich I.A., Zolotukhin I.S. Oxidation temperatures of WC-Co cemented tungsten carbides....................................... 199 Pribytkov G.A., Baranovskiy A.V., Firsina I.A., Akimov K.O., Krivopalov V.P. Study of Fe-matrix composites with carbide strengthening, formed by sintering of iron titanides and carbon mechanically activated mixtures................ 212 EDITORIALMATERIALS 224 FOUNDERS MATERIALS 235 CONTENTS
OBRABOTKAMETALLOV Vol. 26 No. 2 2024 technology Preparation of coatings with high infrared emissivity Vyacheslav Sirota 1, a, Sergey Zaitsev 1, b, Mikhail Limarenko 1, c, Dmitry Prokhorenkov 1, d, Mikhail Lebedev 1, e, Anton Churikov 1, f, Alexey Dan’shin 2, g 1 Belgorod State Technological University named after V.G. Shukhov, 46 Kostyukova st., Belgorod, 308012, Russian Federation 2 JSC “Shebekinsky Machine-Building Plant”, 11 Oktyabrskaya st., Shebekino, 309290, Russian Federation a https://orcid.org/0000-0003-4634-7109, zmas36@mail.ru; b https://orcid.org/0000-0003-0122-1908, sergey-za@mail.ru; c https://orcid.org/0000-0001-6699-6910, mclam@mail.ru; d https://orcid.org/0000-0002-6455-8172, bstu-cvt-sem@yandex.ru; e https://orcid.org/0000-0003-3194-9238, michaell1987@yandex.ru; f https://orcid.org/0000-0002-1829-2676, churikov.toni@mail.ru; g https://orcid.org/0009-0009-6998-8241, aldans@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2024 vol. 26 no. 2 pp. 23–37 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.2-23-37 ART I CLE I NFO Article history: Received: 13 December 2023 Revised: 26 February 2024 Accepted: 20 March 2024 Available online: 15 June 2024 Keywords: Detonation spraying High emissivity coating Funding The research was carried out within the framework of the Complex Project No. 30/22 dated 10/12/22 within the framework of Agreement No. 075–112023-017 dated 02/13/2023 “Creation of high-tech production of composite cutting elements of machines and thermal equipment for processing agricultural products”. Acknowledgements The research was carried out using the equipment of the Center for High Technologies of BSTU named after V.G. Shukhov. ABSTRACT Introduction. One of the promising modern methods of coating formation is detonation gas dynamic sputtering. Coatings obtained by this method have high adhesion to the substrate, dense structure and specified functional properties. Development of technology for obtaining functional coatings with high emission coefficient in the infrared range is an urgent need for the development of high-temperature industrial processes and technologies. High-temperature industrial processes consume a large amount of energy, so improving the energy efficiency of industrial equipment is considered as one of the ways to overcome the ever-growing energy crisis. To this end, coatings with high infrared emissivity have been developed for industrial furnaces. These coatings are usually applied to the furnace walls, which significantly improves energy efficiency by increasing heat transfer from the heat-emitting surfaces of the furnace. The purpose of the work is to obtain coatings with high emission indices in the infrared range for further recommendation of its use in baking ovens of Shebekinsky machine-building plant. Methods for studying coating specimens obtained by detonation gas-thermal method: scanning electron microscopy, X-ray phase analysis, energy dispersive analysis, infrared spectroscopy. Results and discussion. The microstructure, phase composition, emissivity and thermal cycling resistance of Fe2O3; Al2O3 + 10 % Fe2O3; Ti + 10% Fe2O3 coatings obtained by detonation gas-dynamic powder spraying are investigated in this work. The results of the study showed that the obtained coatings have a dense structure, increased emissivity and resistance to thermal treatment cycles, as a result of which the structure of the crystal lattice of the coatings does not change. For citation: Sirota V.V., Zaitsev S.V., Limarenko M.V., Prokhorenkov D.S., Lebedev M.S., Churikov A.S., Dan’shin A.L. Preparation of coatings with high infrared emissivity. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 2, pp. 23–37. DOI: 10.17212/1994-6309-2024-26.2-23-37. (In Russian). ______ * Corresponding author Sirota Vyacheslav V., Ph.D. (Physics and Mathematics), Director Belgorod State Technological University named after V.G. Shukhov, 46 Kostyukova st., 308012, Belgorod, Russian Federation Tel.: +7 904 539-14-08, e-mail: zmas36@mail.ru
OBRABOTKAMETALLOV technology Vol. 26 No. 2 2024 Introduction Ceramic composite materials have been actively used during the last decade for protection against abrasion and thermal corrosion. There have also been a number of works [1–6] devoted to the study of the emissivity of ceramic composite materials in order to use it as coatings on the heat-transferring surfaces of industrial furnaces to increase energy efficiency. The heat treatment process is one of the most common technological operations in all industries. The heat energy transfer in the furnace occurs through convection and radiation mechanisms, but radiation heat transfer becomes dominant with increasing temperature [7]. The main criterion that characterizes the efficiency of radiation heat transfer is the emissivity of the heat-emitting surfaces, in industrial heating furnaces. Such surfaces are internal walls, gas ducts and coils, depending on the design and type of furnace. Increasing the energy efficiency of industrial heating furnaces is currently considered as one of the promising ways to overcome the ever-growing energy crisis, because it is in heating processes that a large amount of energy is wasted [8]. To this end, ceramic composite coatings with high emissivity and thermal stability during operation consisting of powder compositions of Fe2O3, Al2O3 + 10 % Fe2O3, Ti + + 10 % Fe2O3 were developed and investigated. The effect of the presence of iron oxide and aluminum oxide in the coating on increasing emissivity was shown by other researchers [9–11]. Previously developed coatings were applied in different ways on the heat-transmitting walls of the furnace, which significantly improved the energy efficiency of heat energy transfer [9–12]. The emissivity coefficient of a material is the ability of its surface to radiate energy through radiative heat transfer; numerically this characteristic can be expressed as the ratio of the energy radiated by a particular material to the radiated energy of a absolutely black body at the same temperature, where a absolutely black body will have a value equal to 1, and for a comparable material the value is in the range from 0 to 1 [13]. At present, many methods have been studied for applying high-emissivity coatings to metal surfaces, for example: sol-gel method, glazing, magnetron sputtering, electron beam vapor deposition, plasma spraying, etc. [14–19]. In the presented work, the possibility of forming coatings with high emissivity coefficient on the heat-emitting surfaces of industrial baking ovens using detonation gas-dynamic spraying is investigated. This method makes it possible to apply coatings with low porosity (1 %) and high adhesion to the base [20], which will ensure the resistance of the coating to thermal cycling. The coating process is carried out by heating and accelerating powders by detonation combustion products of combustible gas mixture of propane, oxygen and air with a frequency of 20 Hz and above, the sprayed particles velocity using this method reaches 1,200 m/s, and the materials utilization rate for oxide ceramic powders is not less than 67 % [21, 22]. The purpose of the work is to obtain coatings with high emission indices in the infrared range for further recommendation of its use in baking ovens of Shebekinsky machine-building plant. To achieve the purpose the following tasks were solved: 1. The compositions were determined and powder compositions of Fe2O3, Al2O3 + 10% Fe2O3, Ti + + 10 % Fe2O3 were prepared. 2. Technological parameters for applying powder compositions using the detonation gas-dynamic method were determined. 3. The structure and phase composition of the obtained coatings were investigated. 4. The emissivity of the obtained coatings was determined. 5. The thermal stability of the obtained coatings was studied. Research methodology As raw components for the creation of coatings, powders Ti (PTS-1, purity 99 %), Al2O3 (ChDA, purity 98.5 %), Fe2O3 (extra-pure 2–4, purity 99.7 %) were purchased. The characteristics of the purchased powders are given in Table 1. Mixing of powder compositions of Al2O3, PTS-1 and Fe2O3 was carried out mechanically in a Fritsch Pulverisette 6 planetary mill at a mass ratio of balls to mixture of 2:1 at a speed of 200 rpm for 5 min.
OBRABOTKAMETALLOV Vol. 26 No. 2 2024 technology Coating was carried out by detonation gas dynamic spraying using a robotic complex (Fig. 1) for detonation spraying of coatings, consisting of a multi-chamber shaped-detonation device (MCDS), a gas post, a gantry robot, and a special powder feeder, which provides dosing and periodic powder feeding into the MCDS. Powder injection into the combustion chamber of the MCDS in the process of detonation of the combustible gas mixture ensures its heating and acceleration. Heated powders hit the substrate surface at high speed, creating a dense composite coating [23–25]. Ta b l e 1 Powders used for coatings Name, grade Manufacturer Method of obtaining Particle size distribution, µm d(10) d(50) d(90) Ti powder, PTS-1 JSC POLEMA Tula, Russia Amalgam metallurgy method 9.54 24.69 50.76 Al2O3 powder Donetsk Chemical Reagents Plant Initial material calcination in a halogen-containing atmosphere 2.28 19.96 46.36 Fe2O3 powder Donetsk Chemical Reagents Plant Utilization of thermal decomposition products of iron 0.23 5.54 27.9 Fig. 1. Robotic complex for detonation coating The right side of Figure 1 shows the assembling sheet of the coated baking oven. After coating all the heat-transferring surfaces of the oven components, the baking chamber is assembled. The baking chambers in the baking ovens of the Shebekinsky Machine-Building Plant are made of St3 steel. The finished baking oven of the Shebekinsky Machine-Building Plant is shown in Figure 2. A series of experimental specimens of coatings on a substrate of St3 steel with dimensions of 40×40 mm (3 specimens for each coating material) were fabricated to study the microstructure, phase composition, resistance to thermal cycling and emissivity. Before coating, the surface of experimental specimens was cleaned from oil contamination with hexane and subjected to sandblasting. Sandblasting was carried out at a pressure of 0.3 MPa with dry quartz sand with grain size 1–3 mm up to the 3rd class of purity according to GOST 9.402-82. Afterwards, residual
OBRABOTKAMETALLOV technology Vol. 26 No. 2 2024 Fig. 2. Appearance of a baking oven of JSC SHMZ Ta b l e 2 Coating parameters Powder name Flow rate of fuel mixture components (m3/h) Powder consumption (g/h) Spraying distance (mm) air oxygen propane (30 %) + butane (70 %) Fe2O3 1.41*/1.08** 2.87*/3.26** 0.54*/0.65** 11 40 Al2O3 + 10 % Fe2O3 1.41*/1.08** 2.87*/3.26** 0.54*/0.65** 52 70 Ti + 10 % Fe2O3 1.3*/1.54** 2.44*/3.04** 0.56*/0.67** 78 65 * – cylindrical combustion chamber; ** – annular combustion chamber/ contamination was removed from the surface of the metal plate by compressed air not worse than the 1st class of contamination according to GOST 17433. The modes of coating on the surface of the experimental specimens are given in Table 2. The coatingwas applied bymoving the barrel in the vertical scanningmodewith a transverse displacement of 5 mm in one pass. The inner diameter of the barrel was 16 mm, the barrel length was 500 mm, and the detonation frequency was 20 Hz. The barrel displacement in vertical scanning mode for Fe2O3, Al2O3 + + 10 % Fe2O3 and Ti + 10 % Fe2O3 composite coatings was carried out at a speed of 2,000 mm/min, 1,000 mm/min, 1,500 mm/min, respectively. To determine the microstructure and phase composition, the obtained experimental specimens were sawn into 4 parts with dimensions of 20×20 mm using an IsoMet 5000 precision cutting machine. The microstructure, elemental composition and morphology of the obtained coatings were investigated by scanning electron microscopy on a scanning electron microscope Mira 3 LMU (Tescan, Czech Republic). A reflected electron detector was used in high-resolution mode at an accelerating voltage of 15 kV to obtain images of the surface of composite coatings and areas for the study of the elemental composition. The elemental composition of the specimens was studied by energy dispersive spectroscopy (EDS) in the AZtec 3.1 microanalysis system using an X-Max 50 detector (Oxford Instruments NanoAnalysis, High Wycombe, England). The accumulation of EDS spectra and elemental composition distribution maps was carried out at an accelerating voltage of 15 kV, working distance 15 mm. The beam current was set so that the signal level was about 4,000–5,000 pulses per second.
OBRABOTKAMETALLOV Vol. 26 No. 2 2024 technology The phase composition of the coated experimental specimens was analyzed by X-ray diffraction with stepwise scanning of 2θ angles from 10 to 90° with a step of 0.05° on an ARL X’TRA diffractometer (Thermo Fisher Scientific, Switzerland) with Cu-Kα-radiation (λ = 0.1541744 nm). The phase composition was determined according to the standard technique in the PDXL program using the PDF-2 (JCPDS ICDD) powder radiographic standards database (2008). The infrared spectra were measured on an IRS 55/S IR Fourier spectrometer (Bruker, Germany) using a registration monochromator controlled by a personal computer (PC). Diffraction gratings of 300 and 150 shp/mm were used to extend the spectral range. The working spectral range of the gratings was 1.4–4.0 and 2.8–8.0 μm, respectively. Measurements were performed at a spectral slit width of 0.02 μm. The scanning step was chosen to be 10 nm. Due to the high absorption capacity of quartz lenses designed to focus radiation to the input slit of the monochromator in the range from 2.5 µm, the latter were removed and replaced by mirrors. The distance from the heated specimen (coated plate) to the monochromator slit was 60 cm. The focused radiation from the specimens was fed to the input slit of the monochromator using an aluminum mirror with focal length f = 150 mm. Mirror adapters (elliptical aluminum reflectors) were used behind the output slit of the monochromator, the use of which made it possible to collect the output radiation from the monochromator to the receiving area of the photodetector with minimal losses. In the 1.0–4.0 μm range, an automated turret with interference IR light filters switchable at wavelengths of 1.0, 1.6, and 2.0 μm was used to cut off higher-order radiation. In the 4.0–8.0 μm range, additional manually switchable IR light filters were used for a similar purpose. In the extended range of 1.0–10.0 μm, a module from ORIEL INSTRUMENTS (USA) was used as a photodetector (detector), the sensitivity of which did not depend on the radiation wavelength. During preliminary adjustment (debugging) of the recording system (signal search and optimization) in the near-infrared range (1.0–2.0 μm) we used more highly sensitive detectors: InGaAs-photodiodes IGA050-TE2-H (900–1,700 nm), IGA2.2-030-TE2-H (900–2,800 nm) and PbS-photoresistors PbS-050-TE2-H, (900–3,300 nm) of the company “ELECTRO-OPTICAL SYSTEMS INC” (USA-Canada); InGaAsP photodiodes PD24-20TEC1-PR (1,000–2,300 nm), PD25-20TEC1-PR (1,000–2,500 nm), PD36-05PR (1,200– 3,800 nm) of the company “IBSG Company Ltd” (St. Petersburg, Russia). The photodiodes and photoresistors were cooled to optimal temperatures. To increase the signal-to-noise ratio, registration was performed using radiation modulation at the input of the monochromator. The modulation frequency was 500 Hz. The pre-amplified signal from the detectors was fed to the main single-channel amplifier with a synchronous detector Lock-in nanovoltmeter type 232 B (Poland, USA). For spectral measurements of specimens in the temperature range from 100 to 500 °C, a method was developed and a thermoblock (mini oven) with heating of specimens and maintenance of its temperature (relative to the required temperature) with an error of ± 5 °C. The thermoblock consists of a heater, a heat conducting sleeve made of copper (d = 40 mm, thickness h = 8 mm) and a heat-resistant casing. A 20×20 mm specimen was pressed to the copper sleeve using screws. Temperature control was carried out using a calibrated constantan-copper thermocouple inserted into the hole of the copper sleeve. The required specimen temperature was maintained by selecting the heater current. The error in spectra measurements in the vast majority of cases did not exceed ± 5 %. In some cases, when the useful signal exceeded the background (noise) signal only 5–10 times, the error could reach ± 10 %. Thermal cycling of coated specimens was carried out in a muffle furnace. For each test, three specimens were placed on a tray. The tray could be moved in and out of the furnace chamber. An air-cooling system was attached to the outside of the chamber to cool the specimens. The oven temperature was set at 550 °C, as this is the maximum operating temperature of the hottest parts of the heat transfer surfaces of the baking oven. The specimens were kept in the muffle oven for 30 min. Then the moving tray with the specimens was removed from the oven and air cooling was applied to the for 10 min. One thermal cycle consisted of 30 min heating and 10 min air cooling. The specimens underwent 300 cycles to evaluate the effect on the coating.
OBRABOTKAMETALLOV technology Vol. 26 No. 2 2024 Results and their discussion The initial powders are represented by a wide range of particles of different shapes, among which we can distinguish splinter, spongy, droplet, as well as particles of complex shape. The results of the study of morphology and particle size of the initial powders are shown in Figure 3. а b c Fig. 3. Morphology and particle size of the initial powders: PTS-1 (a), Al2O3 (b), Fe2O3 (c)
OBRABOTKAMETALLOV Vol. 26 No. 2 2024 technology The results of the study of the phase composition of the initial powders are summarized in Table 3. The results of the study of the particle size distribution of the initial powders are summarized in Table 4. Figure 4 shows the SEM images of the experimental coating specimens sections. A 5 µm thick coating of Fe2O3 powder was formed on St3 steel (Figure 4, a). The contact zone between the coating and the substrate has no defects or microcracks, which indicates high strength of the joint. The coating applied from a composition of Al2O3 + 10 % Fe2O3 powders (Figure 4, b) is continuous, without chipping, bubbles and through cracks. The thickness of the obtained coating is 50 µm. When studying the structure of the coating formed from the composition of powders Ti + 10 % Fe2O3 (Fig. 4, c), it was found that it has a developed lamellar structure with a large number of interphase boundaries. The coating is dense, there are no cracks and pores, and the coating thickness is 5 µm. The results of energy dispersive spectroscopy are summarized in Table 5. Ta b l e 3 Phase composition of the initial powders Name, grade Phase Spatial group PTS-1 powder Ti 194:P63/mmc Powder PDAAl2O3 γ-Al2O3 227:Fd3m Powder extra-pure 2-4 Fe2O3 α-F2O3 167:R-3c Ta b l e 4 Granulometric composition of the initial powders Name, grade Particle size distribution, µm d(10) d(50) d(90) Ti powder, PTS-1 9.54 24.69 50.76 Powder Al2O3 2.28 19.96 46.36 Powder Fe2O3 0.23 5.54 27.9 a b c Fig. 4. Microstructure and morphology of the cross-section surface of experimental coating samples: Fe2O3 (a), Al2O3 + 10% Fe2O3 (b), Ti + 10% Fe2O3 (c)
OBRABOTKAMETALLOV technology Vol. 26 No. 2 2024 Ta b l e 5 Results of energy-dispersive spectroscopy Coverage Element, weight % O Al Ti Fe Fe2O3 30.1 – – 69.9 Al2O3 + 10% Fe2O3 45.7 49.2 – 5.1 Ti + 10 % Fe2O3 39.6 – 54.1 6.3 Ta b l e 6 Phase of composite coatings Coverage Phase Spatial group Composition, % Fe2O3 Fe3O4 74:Imma 100 Al2O3 + 10 % Fe2O3 α-Al2O3 167:R-3c 54 γ-Al2O3 227:Fd3m 39 Fe3O4 227:Fd-3m 7 Ti + 10 % Fe2O3 TiO2 136:P42/mnm 91 Fe3O4 227:Fd-3m 9 The results of energy dispersive spectroscopy (EDS), confirmed the expected elemental composition of the witness specimens. The composition corresponds to the composition of the initial powders. The results of the study of the phase composition of the coatings are summarized in Table 6. When coating from a composition of Al2O3 + 10 % Fe2O3 powders, a structure consisting of α-Al2O3, γ-Al2O3 and Fe3O4 solid solution phases is formed. The coating obtained from the composition of powders Ti + 10 % Fe2O3 consists of phases TiO2 and Fe3O4. The transition of the Ti phase into the TiO2 phase is due to the oxidation of titanium, which occurs during the formation of the coating. Figure 5 shows the results of measuring the emissivity of experimental specimens of coatings at 450 °С. The dips in the region of 4.25 μm are caused by absorption of carbon dioxide, in the region of 1.82, 3.3, 5.9 and 6.5 μm are caused by steam. Among the experimental specimens obtained, the coating Fe2O3 at 450 °C showed the highest emissivity in the infrared range ε3-7 μm = 0.7 and ε4-5 μm = 0.8. Composite coatings of Al2O3 + 10 % Fe2O3 and Ti + 10 % Fe2O3 have ε3-7 μm = 0.59 and 0.57 , respectively, and ε4-5 μm = 0.67 and 0.66 at 450 °C. Coating Fe2O3 has the main peak of IR radiation in the region of 3–4 μm, which is more promising for use in the baking industry, because the radiation of this spectral range most deeply penetrates into the dough, accelerating the cooking process. According to the results of the analysis of the results of thermal cycling of experimental specimens, it was revealed that the appearance of coatings did not change. The appearance of the coating specimens after thermal cycling is shown in Figure 6. The specimens underwent 300 cycles of thermal cycling without cracks and delaminations. The analysis of X-ray phase diagram showed that after thermocycling there were no changes in the crystal lattice, which indicates a high resistance of coatings to operational temperature changes. The results are presented in Figure 7.
OBRABOTKAMETALLOV Vol. 26 No. 2 2024 technology W(m2‧nm) nm ABB for λ=3-7 µm R=8.5 kW/m2, ɛ = 1 Fe2O3 for λ=3-7 µm R=5.9 kW/m2, ɛ = 0,7 Al2O3+10%Fe2O3 for λ=3-7 µm R=5.0 kW/m2, ɛ = 0,59 Ti+10%Fe2O3 for λ=3-7 µm R=4.8 kW/m2, ɛ = 0,57 Steel for λ=3-7 µm R=4.8 kW/m2, ɛ = 0,57 Fig. 5. Spectral emissivity of experimental coating samples at 450°С a b c Fig. 6. Appearance of coating samples after thermal cycling: Fe2O3 (a); Al2O3 + 10 % Fe2O3 (b); Ti + 10 % Fe2O3 (c) Conclusions Coatings Fe2O3; Al2O3 + 10 % Fe2O3, Ti + 10 % Fe2O3, obtained by detonation gas dynamic powder spraying were studied for JSC Shebekino Machine Building Plant, Shebekino. Analysis of the microstructure of the obtained coatings showed that it has a dense lamellar structure with the absence of cracks. The results of high-temperature cyclic heat treatment showed that the obtained coatings are resistant to operating temperatures. X-ray diffraction analysis showed that no changes in the crystal lattice of the coatings occurred under the influence of cyclic heat treatment. The results of infrared spectrometry of the obtained coatings show that at T = 450 °C about 5 kW of power can be obtained per square meter of a coating with a high emission coefficient. According to the
OBRABOTKAMETALLOV technology Vol. 26 No. 2 2024 after thermal cycling after application intensity deg after thermal cycling after application intensity deg after thermal cycling after application intensity deg Fig. 7. Comparison of the results of X-ray phase analysis before and after thermal cycling: Fe2O3 (a); Al2O3 + 10 % Fe2O3 (b); Ti + 10 % Fe2O3 (c) a b b
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