Residual stresses and their effect on abrasive wear resistance of electric arc cored wire coatings

Keywords

cored wires, electrode coatings, structure, stress, wear resistance.

Cite as

Hvozdetskyi V. M., Ostapchuk N. M., Honchar I. M., Hasiy O. B., Zadorozhna Kh. R., Student M. M., and Markovych S. I. Residual stresses and their effect on abrasive wear resistance of electric arc cored wire coatings. Physicochemical Mechanics of Materials. 2026. 62(1), 048-056.

https://doi.org/10.15407/pcmm2026.01.048

Abstract

The influence of first-order stresses on the abrasive wear resistance of arc sprayed coatings (ASC) is investigated. Based on studies of their phase composition and its influence on the level of residual first-order stresses σ_res, an empirical formula for determining these stresses is proposed. Since not only the level of σ_res in the coating but also its cohesive strength σ_B is important for the ASC performance, it is proposed to use their ratio σ_res / σ_В as a characteristic of the ASC cracking susceptibility. It is empirically established that when σ_res / σ_В > 0.75, the coatings are prone to micro­cracking, and when σ_res / σ_В > 0.85, a net­work of cracks is formed in them. Preheating the samples before ASC spraying with cored wires (CW), as well as their tempering after spraying, reduces tensile stress in the coatings, promotes the release of dispersed carbides and borides in their structure and, as a result, significantly increases their abrasive wear resistance.

References

1. Y. Kyryliv, O. Maksymiv, V. Kyryliv, B. Tsizh, V. Vynar, and S. Yermolayenko, “Impact of deformation force by vibration-centrifugal hardening on the properties of the surface nanostructure of steel 40Kh,” J. of Mater. Eng. and Performance, 34, 29182-29192 (2025). https://doi.org/10.1007/s11665-025-11450-9
2. V. Kyryliv, V. Gurey, O. Maksymiv, I. Hurey, and Y. Kulyk, “Influence of the deformation mode on the force conditions of formation of the surface nanostructure of 40Kh steel,” Mater. Sci., 57, Is. 3, 422-427 (2021). https://doi.org/10.1007/s11003-021-00556-9
3. V.I. Kyryliv, V.I. Zakiev, and O.V. Maksymiv, “Change of the modulus of elasticity of the surface nonasrtuctured Layer on U8 Steel,” Mater. Sci. 58, Is. 6, 795-800 (2023). https://doi.org/10.1007/s11003-023-00732-z
4. D.A. Lesyk, B.N. Mordyuk, S. Martinez, V.V. Dzhemelinskyi, D. Grzesiak, D. Grochała, and A. Lamikiz, “Laser-based additive manufacturing and mechanical surface post-processing: Comparison of barrel finishing, shot and ultrasonic peening for corrosion resistance improvement of superalloy,” Lasers in Manufacturing and Mat. Proc., 10, 702-734 (2023). https://doi.org/10.1007/s40516-023-00231-8
5. I.P. Shatskyi, L.Y. Ropyak, and M.V. Makoviichuk, “Strength optimization of a two-layer coating for the particular local loading conditions,” Strength of Mater., 48, Is. 5, 726-730 (2016). https://doi.org/10.1007/s11223-016-9817-5
6. L. Ropyak, T. Shihab, A. Velychkovych, O. Dubei, T. Tutko, and V. Bilinskyi, “Design of a two-layer Al-Al2O3 coating with an oxide layer formed by the corrosion and wear protection of steel,” Progress in Phys. of Met., 24, Is. 2, 319-365 (2023). https://doi.org/10.15407/ufm.24.02.319
7. Y. Kyryliv, V. Kyryliv, B. Tsizh, and O. Maksymiv, “Resistance of surface nanostructures and ultrafine grain structures on steel 40Kh to wear and cavitation-erosive destruction,” Appl. Nanosci., 12, Is. 4, 1085-1090 (2022). https://doi.org/10.1007/s13204-021-01751-5
8. V.I. Kyryliv, B.P. Chaikovs’kyi, O.V. Maksymiv, and A.V. Shal’ko, “Contact fatigue of 20KHN3A steel with surface nanostructure,” Mater. Sci. 51, Is. 6, 833-838 (2016). https://doi.org/10.1007/s11003-016-9909-1
9. J.N. Ndumia, M. Kang, B.V. Gbenontin, J. Lin, and S.M. Nyambura, “A review on the wear, corrosion and high-temperature resistant properties of wire arc-sprayed Fe-based coatings,” Nanomaterials, 11, Is. 10 (2021). Art. no. 2527. https://doi.org/10.3390/nano11102527
10. М.М. Student, H.V. Pokhmurs’ka, and K.R. Zadorozhna, “Structure and wear resistance of VC-FeCr and VC-FeCrСо coatings obtained by supersonic flame spraying,” Mater. Sci., 54, Is. 1, 22-29. (2018). https://doi.org/10.1007/s11003-018-0152-9
11. М.М. Student, H.V. Pokhmurs’ka, Kh.R. Zadorozhna, H.H. Veselivs’ka, V.М. Hvozdets’kyi, and Y.Y. Sirak, “Corrosion resistance of VC-FeCr and VC-FeCrСо coatings obtained by supersonic gas-flame spraying,” Mater. Sci., 54, Is. 4, 535-541 (2019). https://doi.org/10.1007/s11003-019-00214-1
12. T.R. Stupnyts’kyi, M.M. Student, H.V. Pokhmurs’ka, and V.M. Hvozdets’kyi, “Optimization of the chromium content of powder wires of the Fe-Cr-C and Fe-Cr-B systems according to the corrosion resistance of electric-arc coatings,” Mater. Sci., 52, Is. 2, 165-172 (2016). https://doi.org/10.1007/s11003-016-9939-8
13. C. Lima, R. Libardi, R. Camargo, H. Fals, and V. J. Ferraresi, “Assessment of abrasive wear of nanostructured WC-Co and Fe­based coatings applied by HP­HVOF, flame, and wire arc spray,” Therm. Spray. Techn., 23 (2014). Art. no. 10971104. https://doi.org/10.1007/s11666-014-0101-6
14. M. Student, V. Hvozdetskyi, T. Stupnytskyi, O. Student, P. Maruschak, O. Prentkovskis, and P. Skačkauskas, “Mechanical properties of arc coatings sprayed with cored wires with different charge com-positions,” Coatings, 12, Is. 7 (2022). Art. no. 925. https://doi.org/10.3390/coatings12070925
15. A. Harju, Properties of High Velocity Arc Sprayed Coatings, Master of Sci. Thesis, – Tampere University of Technology (2017), 118 p.
16. R. Wang, L. Xu, T. Zhang, and X. Huang, “The properties of the high productive high velocity arc sprayed coatings and its applications,” in Proc. Int. Therm. Spray Conf. Adv. in Technol. and Applic. (ITSC-2004) (May 10-12, 2004, Osaka, Japan). Paper No: itsc2004p0001.
17. R. Bolot, M. Planche, H. Liao, and C. Coddet, “A three-dimensional model of the wire-arc spray process and its experimental validation,” J. Mater. Proc. Techn., 200, Iss. 1-3, 94-105 (2008). https://doi.org/10.1016/j.jmatprotec.2007.08.032
18. M. Student, V. Gvozdetsky, O. Student, O. Prentkovskis, P. Maruschak, O. Olenyuk, and L. Titova, “The effect of increasing the air flow pressure on the properties of coatings during the arc spraying of cored wires,” Strojnícky Časopis – J. Mech. Eng., 69, No. 4, 133-146 (2019). https://doi.org/10.2478/scjme-2019-0048
19. X. Wang, J. Heberlein, E. Pfender, and W. Gerberich, “Effect of nozzle configuration, gas pressure, and gas type on coating properties in wire arc spray,” J. of Therm. Spray Technol., 8, Is 4, 565-575 (1999). https://doi.org/10.1361/105996399770350269
20. A. Newbery and P. Grant, “Large arc voltage fluctuations and droplet formation in electric arc wire spraying,” Powder Metallurgy, 46, Is. 3, 229-235 (2003). https://doi.org/10.1179/003258902225000000
21. S. Toma, C. Bejinariu, R. Baciu, and S. Radu, “The effect of frontal nozzle geometry and gas pressure on the steel coating properties obtained by wire arc spraying,” Surf. and Coat. Technol., 220, 266-270 (2013). https://doi.org/10.1016/j.surfcoat.2012.11.011
22. I. Gedzevicius and A. Valiulis, “Analysis of wire arc spraying process variables on coatings properties,” J. of Mater. Proces. Technol., 175, Iss. 1-3, 206-211 (2006). https://doi.org/10.1016/j.jmatprotec.2005.04.019
23. G. Bolelli, V. Cannillo, L. Lusvarghi, and S. Riccò Mechanical and tribological properties of electrolytic hard chrome and HVOF-sprayed coatings,” Surf. and Coat. Technol., 200, Is. 9, 2995-3009 (2006). https://doi.org/10.1016/j.surfcoat.2005.04.057
24. Supersonic electric arc spraying of critical parts of rolling stock of railway transport / V. N. Korzhik, N. P. Lyutik, A. A. Chajka, V. I. Tkachuk, I. D. Gos, and Yu. A. Nikityuk // The Paton Welding J. – 2016. – 9. – P. 18-25. https://doi.org/10.15407/tpwj2016.09.04
25. J. Wilden, A. Schwenk. J. P. Bergmann, S. Zimmermann, and K. Landes, “Supersonic nozzles for the wire arc spraying,” in Proc. Int. Therm. Spray Conf. (2005). Paper No: itsc 2005p1068. – Р. 1068-1073. https://doi.org/10.31399/asm.cp.itsc2005p1068
26. Bauyrzhan Rakhadilov, Nurtoleu Magazov, Dauir Kakimzhanov, Dauir Kakimzhanov, Akbota Apsezhanova, Yermakhan Molbossynov, and Aidar Kengesbekov, “Influence of spraying process parameters on the characteristics of steel coatings produced by arc spraying method,” Coatings, 14, Is. 9 (2024). Art. no 1145. https://doi.org/10.3390/coatings14091145
27. K. Bobzin, W. Wietheger, E. Burbaum, and L.M. Johann, “High-velocity arc spraying of Fe-based metallic glasses with high Si content,” J. Therm. Spray Tech., 31, 2219-2228 (2022). https://doi.org/10.1007/s11666-022-01433-w
28. B. Rakhadilov, A. Shynarbek, D. Kakimzhanov, R. Kusainov, A. Zhassulan, and K. Ormanbekov, “Effect of voltage on properties of 30HGSA steel coatings by supersonic supersonic arc metallization method,” Adv. Sci. Technol. Res. J., 18, 113-124 (2024). https://doi.org/10.12913/22998624/190251
29. Z. U. Arif, M. Shah, E.U. Rehman, and A. Tariq, “Effect of spraying parameters on surface roughness, deposition efficiency, and microstructure of electric arc sprayed brass coating,” Int. J. Adv. Appl. Sci., 7, Is. 7, 25-39 (2020). https://doi.org/10.21833/ijaas.2020.07.004
30. M.I. Boulos, P.L. Fauchais, and J.V.R. Heberlein, “Wire arc spraying” in Thermal Spray Fundamentals: From Powder to Part., – Cham: Springer (2021), pp. 467-517. https://doi.org/10.1007/978-3-030-70672-2
31. W. Kraus. and G. Nolze, “Powder cell – a program for the representation and manipulation of crystal structures and calculation of the resulting X-ray powder patterns,” J. Appl. Cryst., 29, 301-303 (1996). https://doi.org/10.1107/S0021889895014920