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Effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process

Protective coating has been one of the most effective corrosion mitigation methods. Therefore, it has been utilized to protect steel substrates for decades. Among various coating techniques, the twin wire arc spray (TWAS) process has been widely adopted in surface engineering to protect components d...

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Main Authors: Ismail, Nur Suhaili, Fadil, Nor Akmal, Abu Bakar, Tuty Asma
Format: Article
Published: Universiti Putra Malaysia 2022
Subjects:
TJ Mechanical engineering and machinery
Online Access:http://eprints.utm.my/id/eprint/98504/
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&ved=2ahUKEwiCqKm-7rn8AhVuTmwGHUptCUMQFnoECAsQAQ&url=https%3A%2F%2Fwww.malaysianjournalofmicroscopy.org%2Fojs%2Findex.php%2Fmjm%2Farticle%2Fdownload%2F630%2F331&usg=AOvVaw0ontrYX__u8FYb8RwO7BXb
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spelling my.utm.985042023-01-11T03:53:59Z http://eprints.utm.my/id/eprint/98504/ Effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process Ismail, Nur Suhaili Fadil, Nor Akmal Abu Bakar, Tuty Asma TJ Mechanical engineering and machinery Protective coating has been one of the most effective corrosion mitigation methods. Therefore, it has been utilized to protect steel substrates for decades. Among various coating techniques, the twin wire arc spray (TWAS) process has been widely adopted in surface engineering to protect components due to its cost efficiency and flexibility. It promotes superior coating quality: low porosity, high hardness, and high adhesion. However, it is crucial to set the proper coating process parameters as coating properties produced via TWAS usually have high roughness and low adhesion to substrates. In this study, two different wires feedstock of Al and Zn were used to produce a pseudo-alloy of Al-50Zn alloy coating on mild steel substrates. In this research, the stand-off distance (SOD) parameter was varied at 100, 150, 200, 250, and 300 mm. The effect on the properties of developed coating layer on microstructure, thickness, hardness, roughness, and adhesion was investigated. The microstructure and morphological analyses were conducted using SEM and the phase analysis using XRD. Results have shown that the samples prepared at 100 mm have demonstrated the best coating quality compared to others and there are pronounced correlations between process parameters and all coating properties. The average thickness of the coating at 100 mm SOD was recorded to be the lowest at 230 μm with the highest hardness and adhesion values, 109 Hv and 8.3 MPa, respectively and the lowest surface roughness of 5.1 microns. Contrasts with coating prepared at 300 mm SOD that has demonstrated poor qualities in both microstructural and mechanical properties. Universiti Putra Malaysia 2022 Article PeerReviewed Ismail, Nur Suhaili and Fadil, Nor Akmal and Abu Bakar, Tuty Asma (2022) Effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process. Malaysian Journal of Microscopy, 18 (1). pp. 256-269. ISSN 1823-7010 https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&ved=2ahUKEwiCqKm-7rn8AhVuTmwGHUptCUMQFnoECAsQAQ&url=https%3A%2F%2Fwww.malaysianjournalofmicroscopy.org%2Fojs%2Findex.php%2Fmjm%2Farticle%2Fdownload%2F630%2F331&usg=AOvVaw0ontrYX__u8FYb8RwO7BXb
institution Universiti Teknologi Malaysia
building UTM Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Teknologi Malaysia
content_source UTM Institutional Repository
url_provider http://eprints.utm.my/
topic TJ Mechanical engineering and machinery
spellingShingle TJ Mechanical engineering and machinery
Ismail, Nur Suhaili
Fadil, Nor Akmal
Abu Bakar, Tuty Asma
Effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process
description Protective coating has been one of the most effective corrosion mitigation methods. Therefore, it has been utilized to protect steel substrates for decades. Among various coating techniques, the twin wire arc spray (TWAS) process has been widely adopted in surface engineering to protect components due to its cost efficiency and flexibility. It promotes superior coating quality: low porosity, high hardness, and high adhesion. However, it is crucial to set the proper coating process parameters as coating properties produced via TWAS usually have high roughness and low adhesion to substrates. In this study, two different wires feedstock of Al and Zn were used to produce a pseudo-alloy of Al-50Zn alloy coating on mild steel substrates. In this research, the stand-off distance (SOD) parameter was varied at 100, 150, 200, 250, and 300 mm. The effect on the properties of developed coating layer on microstructure, thickness, hardness, roughness, and adhesion was investigated. The microstructure and morphological analyses were conducted using SEM and the phase analysis using XRD. Results have shown that the samples prepared at 100 mm have demonstrated the best coating quality compared to others and there are pronounced correlations between process parameters and all coating properties. The average thickness of the coating at 100 mm SOD was recorded to be the lowest at 230 μm with the highest hardness and adhesion values, 109 Hv and 8.3 MPa, respectively and the lowest surface roughness of 5.1 microns. Contrasts with coating prepared at 300 mm SOD that has demonstrated poor qualities in both microstructural and mechanical properties.
format Article
author Ismail, Nur Suhaili
Fadil, Nor Akmal
Abu Bakar, Tuty Asma
author_facet Ismail, Nur Suhaili
Fadil, Nor Akmal
Abu Bakar, Tuty Asma
author_sort Ismail, Nur Suhaili
title Effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process
title_short Effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process
title_full Effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process
title_fullStr Effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process
title_full_unstemmed Effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process
title_sort effect of stand-off distance on the microstructural, mechanical and physical properties of al-zn pseudo-alloy coating prepared via wire arc spray process
publisher Universiti Putra Malaysia
publishDate 2022
url http://eprints.utm.my/id/eprint/98504/
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&ved=2ahUKEwiCqKm-7rn8AhVuTmwGHUptCUMQFnoECAsQAQ&url=https%3A%2F%2Fwww.malaysianjournalofmicroscopy.org%2Fojs%2Findex.php%2Fmjm%2Farticle%2Fdownload%2F630%2F331&usg=AOvVaw0ontrYX__u8FYb8RwO7BXb
_version_ 1755872318313201664
score 13.223943

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