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Investigation on Slurry Erosive Wear Behaviour of HVOF-Sprayed Al2O3–CeO2 Coatings on AZ91 Alloy

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Abstract

In the present study, slurry erosive behaviour of AZ91 alloy with and without ceramic composite coatings is studied. The coating materials selected for applying on the surface of AZ91 alloy were Al2O3, Al2O3–20%CeO2, and Al2O3–40%CeO2 and the coating technique adopted was high-velocity oxy-fuel (HVOF). The developed composite coatings were subjected to microstructure analysis using scanning electron microscope (SEM), X-ray diffraction studies to understand the formation of different phases in the deposited coatings, microhardness test to know the resistance against indentation, and slurry erosion test to obtain mass loss. The effect of varying particle size (100–400 μm), slurry concentration (50–150 g/l), and slurry speed (500–1500 rpm) on mass loss was studied. The cross-sectional SEM micrographs of all coating showed good adhesion with the AZ91 surface and minimal porosity content. The microhardness was found to be highest for the Al2O3–40%CeO2 coating while lowest value was recorded for uncoated AZ91 alloy. With respect to coating composition, the slurry erosion test showed decrease in the mass loss with increasing CeO2 content in the composite coating. On the other hand, increase in the erodent particle size, slurry concentration and slurry speed led to increase in the mass loss for all materials.

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Authors and Affiliations

  1. Department of Mechanical Engineering, JAIN University, Bangalore, India

    Kaushik V. Prasad (Assitant Professor)

  2. Department of Mechanical Engineering, JAIN University, Bangalore, India

    Adarsha Hiriyannaiah (Professor and Head)

  3. Department of Mechanical Engineering, Dayananda Sagar College of Engineering, Bangalore, India

    R. Keshavamurthy (Professor)

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  1. Kaushik V. Prasad
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  2. Adarsha Hiriyannaiah
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  3. R. Keshavamurthy
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Correspondence to Kaushik V. Prasad.

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Prasad, K.V., Hiriyannaiah, A. & Keshavamurthy, R. Investigation on Slurry Erosive Wear Behaviour of HVOF-Sprayed Al2O3–CeO2 Coatings on AZ91 Alloy. J. Inst. Eng. India Ser. D 104, 661–675 (2023). https://doi.org/10.1007/s40033-022-00421-2

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