Mechanical characteristics of electric arc coatings sputtered on St3 steel and D16 aluminum alloy

Keywords

aluminium substrate, steel substrate, cored wires, electric arc coatings, sputtering, Laval nozzle, structure, air jet speed, cohesive strength, residual stress level.

Cite as

Hvozdetskyi V. M., Student M. M., Zadorozhna Kh. R., Veselivska H. H., Markovych S. I., and Mozola N. Z. Mechanical characteristics of electric arc coatings sputtered on St3 steel and D16 aluminum alloy. Physicochemical Mechanics of Materials. 2025. 61(2), 014-022.

https://doi.org/10.15407/pcmm2025.02.014

Abstract

Electric arc coatings (EAC), sprayed with the Fe–Cr–Si–Mn–B–C cored wires (CW) alloying system with an exothermic charge based on boron carbide powder, is investigated. The content of boron in the FCW varied within 0–2 mass% to obtain a microhardness of coatings in the range of 500–1000 HV_0.3 for the restoration of lightly and heavily loaded parts of units. The chromium content in the CW varied within 6–17 mass% to form coatings on parts that operate in technological and corrosive environments. Since the performance characteristics of the coatings, also depend on the substrate material and the air jet pressure during their deposition, they were sprayed onto aluminium and steel sub­strates at subsonic (0.6 MPa, 300 m/s) and super­sonic (1.2 MPa, 600 m/s) air jet pressures. The supersonic speed was achieved due to the nozzle system of coating spraying using double Laval nozzles. The ratio of residual tensile stresses of the first kind σ_res to their cohesive strength σ_s (σ_res/σ_s) was used as an indicator of the resistance of coatings to cracking. It was shown that cracks began to form in coatings for which σ_res/σ_s > 0.75, while at σ_res/σ_s > 0.85, a network of cracks was formed in the coatings. It was found that σ_res in the coatings sputtered on an aluminium substrate was lower than in those sputtered on steel, which is due to the higher coefficient of thermal expansion of D16 aluminium alloy than of St3 steel.

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