EFFECT OF COATINGS ON TRIBOLOGICAL CHARACTERISTICS OF LOW CARBON STEEL

International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN (P): 2249–6890; ISSN (E): 2249–8001 Vol. 10, Issue 3, Jun 2020, 823– 836 © TJPRC Pvt. Ltd.

EFFECT OF COATINGS ON TRIBOLOGICAL CHARACTERISTICS OF LOW CARBON STEEL R. S. MISHRA, MANOJ KUMAR GUPTA* & AMIT KHATRI Research Scholar, Department of Mechanical Engineering, Delhi Technological University, Delhi. India ABSTRACT The purpose of the study is to investigate the effect of coatings (hard chrome plating & plasma nitriding) on Tribological characteristics of low carbon steel (AISI 1020). A Tribotester of pin-on- disc type is used in determining the coefficient of friction and the amount of the wear. The experiment was performed on a mild steel (C-0.20%) disc of and aluminum silicon alloy (9% Si) pin is used. The test of friction force and wear behavior was done experimentally and shows that the coated disc of Mild Steel was slightly less than that of the heat-treated Mild Steel disc. Hence, a comparison was done between the effects of chrome plating, plasma nitriding and uncoated which resulted in the hard chromium coating to be effective in reducing the friction and wear in considerable amount. The wear for uncoated disc leads more, whereas wear for coated was slightly less than heat treatment’s wear when operated on different RPM’s i.e. (319, 764, and 1433). The chrome coated disc resulted increase in the Vickers hardness value. The overall results of this experiment is that plasma Blackening) and heat treated (Plasma Nitriding) mild steel on the dry sliding wear behavior of the casted aluminum silicon alloy will Increases the Surface Hardness, Lowers the amount of Wear and Lowers the Coefficient of Friction.

KEYWORDS: Heat Treatment, Plasma Nitriding, Coating, Hard Chrome Coating, Nickel Plating & Blackening

Received: Apr 16, 2020; Accepted: May 06, 2020; Published: Jun 01, 2020; Paper Id.: IJMPERDJUN202074

Original Article

nitriding is better than currently available coatings and effect of different coatings (Hard Chrome Plating, Nickle Plating,

1. INTRODUCTION Low carbon steels are metallic materials used for making numerous mechanical fundamentals including spindles of machines tools, bolts, shafts, keys and gears [1]. In point of the performance restrictions, the lifetime of those latter might be limited. In order to triumph over this limit, it is advisable to continue to a surface exercising such as nitriding that to improve few attributes of the substance like toughness, wear and corrosion resistance [2]. Wear and tear failure of steel material is one of the unavoidable issues in steel metal industry. It is one of the worst destructive affects to which steels are subjected. Nearly each part that moves will cause and is exposed to wear simultaneously bringing approximately and undergoing progressive destruction. Steel may wear away in many different ways which includes adhesion, abrasion, surface fatigue and erosion-corrosion, of those numerous modes of wear. Adhesive wear and abrasive wear are very often encountered in manufacturing situation. Majorities of wear and tear problems are related to improper material selection even though components may fail due to insufficient lubrication, defective design, excessive handling and dis-operation. Beside material properties, wear rate can also be linked to chemical composition, quantity contents of various microstructural constituent, operating loads, sliding velocity etc.

Hardness [3] is the most commonly used term in wear theory however this term is insufficient itself while dissimilar materials are under consideration. Tribologists have additionally suggested [4] that yield strength and work hardening index would possible have protruding role on wear. It has also been shown [5] that harder aterials www.tjprc.org

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do not usually have higher wear resistance.

Mild steel is taken into consideration of low carbon steel as it was described as holding a less carbon amount of 0.05–0.25%. Mild steel was soft, extraordinary formable, and may be used for automobile frame parts, plates, and cord products. At the higher side of the less carbon amount scale, and along the inclusion of manganese of as much as 1.5%, mechanical properties are suitable for stampings, forgings, seamless tubes, as well boiler plates. [6]. Mild steel is chosen as it’s readily weldable as the electric current passes through the material without distorting the form of the material. Abrasive wear, adhesion wear, corrosive wear, erosion wear, fatigue wear and fretting wear are different types of wear.

In this experimental work, a mild steel material and aluminum silicon alloy to be chosen for the testing. A mild steel disc and an aluminum silicon alloy pin to be fabricated and machined to required dimensions. For the testing, a Mild Steel disc of 165 mm diameter and 10 mm thickness t o b e prepared. Pin of 20mm diameter and 100 mm length to be casted by using the usage of aluminum and 10% silicon. Further pin of 10 mm diameter and 30 mm length to be used for the testing. Hardness is measured by way of Vickers hardness testing technique and measurement of wear & friction force is on rotary kind pin on disc tribotester DUCOM TR-20E make with the WINDUCOM 2008 software program for data and graph. In this check, take the records of hardness, co-efficient of friction and wear force by experiment for uncoated, coated and heat-treated disc & evaluate it with each other. After comparing the records, we discover that the hard chrome coated disc is higher than other coating (nickel plating & blackening) and the heat treated by means of plasma nitriding disc is higher than hard chrome disc.

Nitriding procedure could be generated through several techniques including gas, salt bath, laser and plasma nitriding [7–10]. Plasma nitriding is a financially effective technique of surface therapy utilizing glow discharge era to initiate nitrogen into the surface of a substance [11]. Plasma nitriding can be accomplished both at high or low pressure [12]. The plasma immersion ion implementation nitriding (PIII nitriding) is a physical surface alteration technique belonging to the plasma nitriding methods. PIII-nitriding has determined to be successful in the temperature variety of 250–500 ◦C for carbon steels [13–15]. In this implantation procedure, the samples were absorbed in plasma and were influenced with the support of using high negative voltage pulses. The space charge sheath area made through the implementation of an excessive unfavorable influence voltage speeds the favorable ions (generated in the plasma) toward the samples to be installed to their surfaces [16–20].

The samples have been technically smoothened to a surface finish by the use of Silicon carbide (SiC) emery papers (starting from 200 to 2400 grade), accompanied through an ultrasonic cleaning in acetone and alcohol bath for 10 min earlier to therapy by way of plasma nitriding. The room has first removed to a foundation force of nearly 10−3 mTorr, and the functioning strain of 60 mTorr has been executed via introducing nitrogen to the complex. Prior to the begin of ion installation, the native oxide layer on the substrate on top.

Figure 1: Schematic Diagram of Plasma Nitriding on Disc Surface Impact Factor (JCC): 8.8746

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Hard chrome plating is an electroplating technique wherein chromium was placed from a chromic acid solution.

Chrome plating was utilized for wear and corrosion opposition in further to its tribological (low friction) attributes. Width of Hard chrome plating scales from 2 to 250µm. Surface finish achieved from 20 to 60 µm, this process can be performed at a temperature from 400 – 550°C. So that plasma nitriding heat treated disc is better co-efficient of friction, lesser wear rate, self-lubricated, corrosion resistant.

2. LITERATURE REVIEW [21] Yang et al (2011) described about hard chrome coating and its effects. Contrast to standard covering techniques, hard chrome coating is effective, cost-effective, well understood and without problems carried out. Typically, the thickness of hard chrome coating is set 10~500μm, and the microstructure is extraordinarily fine, consisting a completely less quantity of oxide incursions and micro cracks.

[22] Pandey et al (2016) presented an assessment paper on copper coating of ABS. ABS stands for acrylonitrilebutadiene-styrene contains almost negligible corrosion and erosion with high strength to weight ratio.

[23] Shibe et al. (2013) presented an assessment paper on surface coatings. Surface coating for the manufacturing of substances, tools and device components that need the proper surface effects like corrosion, erosion as well wear resistance.

[24] Khunte et al. (2015) described about the various heat treatment techniques like Normalizing, hardening, tempering. From the various experiments carried via authors, it is concluded that tensile power of mild steel for generalizing heat-treated specimen was greater than different heat treated or with no heat treated specimens.

[25] Nadum et al.(2014) defined about how chrome and presence of manganese enables the formation of carbides where these carbides are considered to be harder than iron carbide in the case of its formation, as though they are determined with the presence of different elements that consist a complex carbides, as the presence of nickel inside the iron contributes to deposit the Graphite independently which ends up to a decrease in mechanical properties, however those few rate of carbon assist to from Graphite independently.

[26] Nasir et al described approximately Heat treatment heating technique which usually takes vicinity on special metals and usually keep them at a constant temperature for the proper duration of time relying on the thickness of the version to bring exchange to the inner structure accompanied by way of a change in the natural and mechanical properties of those metals.

[27] Stoian et al (2015) provided a review paper on chrome plating of steel bars. The chromium electrolytic deposited is silver color and is very hard (600-1200 HB). Chromium is deposited usually tough without intermediate layers steels with decrease hardness value of 56 - 60 HRC. It might also settle on surfaces reconditioned parts made from steel, cast iron, copper, brass, aluminium alloys etc. Chromium coatings are used for decorative purposes protecting to increase wear resistance (hard chrome plating).

[28] Logan et al (2011) discussed approximately Causes of Effects of Chromium Plating on Endurance Limits of Steels. Three feasible explanations for the factthat the endurance limits of the steels had been reduced by means of the chromium late have been proposed. www.tjprc.org

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[29] Widodo et al (2015) described approximately the optimization of nickel chrome coating to get best grade quality hardness. Metal corrosion is degradation of first rate of metallic material as a result of electrochemistry reaction surface of material with its environment.

[30] Adetunji et al (2016) discussed about Case toughening and water quenching of mild steel rod on its mechanized elements. Mild steel is easily available and cheap having all material properties which might be acceptable for plenty applications.

[31] Madhukar et al. (2017) discussed approximately impact of heat treatment on mechanical properties of steels and titanium. Titanium present inside the earth’s crust at a degree over 0.6% and was thus the fourth maximum plentiful structural metal after aluminium, iron, and magnesium. High strength, low density, and excellent corrosion resistance are the main properties [32] Shibe et al. (2013) supplied a review paper on surface coating and its methods. Surface coating is an economic technique for the manufacturing of materials, tools and gadget parts that need the proper surface effects that include corrosion, erosion and wear resistance.

[33] Ladgaonkar et al. (2014) discussed approximately Selective Coating. The use of selective coatings has been widely hooked up as an industrial application which is used to absorb solar thermal energy [34] Khara et al. (2016) discussed approximately Corrosion resistant Cr-coating on mild steel via powder roll bonding. Chromium powder coating on mild steel changed into developed with the aid of roll-bonding observed by means of annealing at 1200°C for distinctive time in hydrogen ecosystem to encourage dispersal connecting and subsequently furnace cooling.

3. METHODOLOGY Preparation of Specimen In this experimental work, a mild steel material and aluminum silicon alloy to be selected for the testing. A mild steel disc and an aluminum silicon alloy pin to be fabricated and machined to required dimensions. For the checking, a Mild Steel disc of 165 mm diameter and 10 mm thickness to be prepared. Pin of 20mm diameter and 100 mm length to be casted by using the use of aluminum and 10% silicon. Further pin of 10 mm diameter and 30 mm length to be used for the check outs.

Material Composition Table 1: Chemical Composition of AISI-1020 Element Content (Wt. %) Iron, Fe 99.08 – 99.53 Carbon, C 0.17 – 0.23 Manganese, Mn 0.30 – 0.60 Phosphorous, P < 0.4 Sulfur, S < 0.05 Table 2: Chemical Composition of AlSi9 Element Content (Wt. %) Si 8.0 – 11.0 Fe 0.55 – 0.65 Cu 0.08 – 1.0 Impact Factor (JCC): 8.8746

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Mn Mg Nl Zn Pb Sn Ti

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0.55 0.10 0.05 0.15 0.05 0.05 0.15

Experimental Procedure The wear and friction coefficient among the mating components to be measured using a pin on disc setup. It includes a disc of 165mm diameter and 10 mm thickness and a pin of about 10mm diameter and 30 mm length. In this experimental work, a mild steel material and aluminum silicon alloy to be chosen for the testing. A slight mild steel disc and aluminum silicon pin to be fabricated and machined to required dimensions. The surface of disc and pin to be cleaned with acetone and dried in atmospheric air well before the begin of each check. A pin on disc wear test rig is used to analyse the impact of various coatings and heat-treated mild steel on the dry sliding wear behavior of the casted aluminum silicon alloy. The wear pin is to be inserted into a fabricated pattern holder. The pin to be held against the mild steel rotating disc below distinctive sliding speeds.

Figure 2: Dimensional Size of Disc and Pin. The quantity of material loss from the two parts is measured by way of frequently measuring the weight of the factor earlier and later the experiment. The distinction of weight gives the quantity of wear loss. This comes out to be in grams. An accurate weighing stability is used for measuring the weight. It has a least count of 0.0001 grams. The Archard’s specific wear rate is then calculated via given below formula: Sw = Vw / (P X D) Where: Sw = Specific wear rate, mm3 / N-m Vw = Volume of wear loss, in mm3 P = Applied load in newton, N D = Sliding Distance in meters, m The specimen should be cleaned properly with the aid of acetone to remove the oil debris attached on the surface of the components. Otherwise it would hamper the weight of the specimen.

The friction rate is calculated from the measured friction influence classified via general load used on the pin by using the checking out machine’s deadweight. www.tjprc.org

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Plasma Nitriding Plasma nitriding, well-known as ion-nitriding, developed by Wehnheldt and Berghause in 1932 though have become productively feasible in the 1970s. In the method the glow expel occurrence was utilized to initiate nascent nitrogen to the surface of a gear and its following dispersion into subsurface layers [35]. The procedure of the plasma-nitriding of gears is executed in a furnace that an electrical voltage was spread among the gear to be used as the cathode, and the furnace as the anode (see Fig. 3).

Initially, the vessel was removed. Gas comprising an aggregate of nitrogen and hydrogen, now and again enhanced with argon or methane, which was initiated. Pressure in the variety of 0.1–10 Torr is about to create a vacuum.

At this point the electric expel is turned on and a glow expel holds position; the nitrogen ion accordingly generated hits the surface of the cathode with excessive kinetic energy emitting heat that outcomes in a sputtering of the cathode that atomizes the cathode (gear) surface substance. Then iron nitride is formed when the atomized ions integrate with nitrogen ions in the plasma that was after placed in a uniform iron nitride layer on the cathode. Then, the iron nitrides were limitedly shattered at the surface of the cathode and then the nitrogen disperses into the gear substance as well as consequences in nitriding [36].

Plasma nitride gears have case hardness of about 58 and 63 HRC and gains superior wear resistance and prolonged carrier life. In addition, the exhaustion power of a gear-tooth might additionally be substantially accelerated.

The formation of provokes on the gear-case effects in lattice extension. In order to preserve its authentic dimensions, the middle maintains the nitride case in contraction. The compressive stress lowers the applied tensile stress on the gear material, growing the fatigue strength.

The investigational parameters of the plasma nitriding on disc are following: ICP origin RF recurrence 13.56 MHz RF strength 240 W Unfavorable diagonal voltage 2.5–4.0 kV Expel gas N2 (100%) Force 60 mTorr surface got eliminated along the help of sputtering with argon gasoline for 20 min and a expel strength of 200 W. The substrate caused unfavorably biased with a voltage starting from 2.5 kV to 4.0 kV and the electricity has approximately near 10 mA. The substrate temperature turned into measured through method of a K-type thermocouple.

The nitride layers had dissemination area as well as a compound quarter, i.e., a white layer. In the dissemination area, nitrogen disperses in steel, generating a stiffened area by action along with solid-solution stiffening. The toughness of this region changes from the surface to the middle and its case depth intensity relies upon in large part on the form of gear steel, the cycle period of nitriding, as well as temperature. The case depth might be as high as 900 µm. The extra nitrides disperse into the gear substance during the treating cycle, leaving a white layer at the pinnacle surface. This white layer is brittle and comparatively inert. Its width was normally beneath 13 µm [36], which can be reduced in addition by way of managing the proportion of nitrogen inside the aggregate of nitrogen and hydrogen for the duration of ion-nitriding. The composition of the white layer provides herbal lubricity and corrosion resistance, furnishing its depth no longer go over 10–12 µm [36, 37].

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Figure 3: Micrograph of Low Carbon Nitride Steel.

Hard Chrome Hard chrome was crucially utilized for several years in implementations which need sliding wear resistance. Hard chromium holds some attributed elements such as comparatively high toughness, precise corrosion resistance and a selfleveling impact. Mixture of the elements has caused utilize in programs wherein the states needs excessive stiffness, less friction, less wear and corrosion resistance. Implementations of Hard Cr plating encompass those inside the piston rods of shock absorbers, piston rings and cylinder liners, and those in the shafts of hydraulic apparatuses, rolls for metal rolling as well as metallic molds [38, 39].

The substrate substance utilized inside the current experiment turned into 1020 commercial mild steel. The chemical mixture become calculated the usage of Energy Dispersive X-Ray (EDX) microanalysis structure. Sliding wear check turned into functioned on samples reduces from the steel bar with sizes of 50 mm diameter and 4 mm thickness. The specimens were removed grease by means of polishing method also cleaned in water to dispose of greases, black corrosive surfaces as well as abrasive dusts caused from slicing manner. The samples have been stressed replaced in temperature of 550 DC for 30 min to take away residual pressures brought about through machining. The specimens have been electrolytically covered using Hard chromium by utilizing an electrochemical cell where the samples have been formulated anode and the cathode become guide in the electrolytic tub comprising answers of 250 g/L chromic acid along with 2.5 g/L sulfuric acid. The anode and cathode has linked to an electricity distribution. The electricity density utilized in this approach became 50 A/dm2 and a voltage of 6 V as well as covering scenarios had differentiated from 5 to 30 min. The electrocoating had been done at a temperature of 55 °C. The samples had been heated through way of immersion in the bath for five min using no electricity after that electricity has steadily risen from zero to the value needed for electroplating that relies upon the cross-sectional region to be covered. After covering, the samples had been washed in purified water and wet using warm air. The Hard chromium covering layer width have been estimated utilizing the covering width gage which encompass micrometer using changes the usage of styluses connected to sensitive electronic amplifiers.

Figure 4: Optical Photomicrograph of the surface of Mild Steel Specimens Coated with Hard Chromium Layer. www.tjprc.org

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Comparison of Data for Wear & Friction

Figure 5: Comparison of Coefficient of Friction (normal, coated and heat treatment) and RPM.

Figure 6: Comparison of Wear (normal, Coated and Heat Treatment) and RPM

4. RESULTS AND DISCUSSIONS The experiment was conducted on low speed, medium speed and high-speed range with the load varied from 5N to 10N. Wear vs Frictional Force

Figure 7: At 319 rpm, the wear increases while frictional force follows the increase in the slope in non-coated material due to the surface being very rough in the starting and its surface finish increases with the coatings and on further Heat Treatment.

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Figure 8: At 319 rpm, the wear increases initially and becomes constant while frictional force follows the increase in the slope in non-coated material due to the surface being very rough in the starting and its surface finish increases with the coatings and on further Heat Treatment.

Figure 9: At 319 rpm, the wear is constant while Frictional Force follows the increase in the slope in non-coated material due to the surface being very rough in the starting and its surface finish increases with the coatings and on further Heat Treatment.

Figure 10: At 319 rpm, the Wear Decreases initially and becomes constant while Frictional Force follows the decrease in the slope in Coated Material.

Figure 11: At 764 rpm, the Wear Increases initially and becomes constant while frictional force follows the increase in the slope in non-coated material due to the surface being very rough in the starting and its Surface Finish increases with the coatings and on further Heat Treatment. www.tjprc.org

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Figure 12: At 764 rpm, the Wear Increases initially and becomes constant while Frictional Force follows the increase in the slope in non-coated material due to the surface being very rough in the starting and its surface finish increases with the coatings and on further Heat Treatment.

Figure 13: At 764 rpm, the Wear Increases initially and becomes constant while Frictional Force follows the constant increase in the slope in non-coated material due to the surface being very rough in the starting and its surface finish increases with the coatings and on further Heat Treatment.

Figure 14: At 764 rpm, the Wear Decreases initially and becomes constant while Frictional Force follows the Decrease in the Slope In Coated Material.

Figure 15: At 764 rpm, the Wear Decreases and becomes Constant while Frictional Force follows the Decrease in the Slope in Coated Material.

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Figure 16: At 1433 rpm, the Wear Becomes Constant while Frictional force follows the increase in the Slope in non Coated Material due to the surface being very rough in the starting and its surface Finish Increases with the coatings and on Further Heat Treatment

Figure 17: At 1433 rpm, the Wear Decreases while Frictional Force Follows the Decrease in the Slope in Coated Material.

5. CONCLUSIONS Research work presented in this paper contains the following conclusions: Surface modification of has been reported to enhance hardness and other mechanical properties, such as growth in resistance, fatigue, and wear.

Nitriding technique is a chemical-warm therapy composed in initiating nitrogen into metallic substances to enhance their surface stiffness, exhaustion life, wear and corrosion resistance. Nitriding surface treatment, achieves superior mechanical properties and resistance to wear. It is to be observed that the impact of nitriding on wear characterization of steel’s capability to offer right wear resistance by increasing their hardness. It is anticipated to be located that pre nitriding of steel can provide tremendous upgrades in coating adhesion, which in the long run leads to development in tribological performance.

Covering is one of the new strategies employed for enhancing the wear resistance as well as weight lifting ability of surfaces in rolling sliding contact. Steel considered with pre-therapy along with the substrate was exposed to pin-on-disc test checks the friction coefficient and improves the wear resistance due to tribology formed. Hard Chrome coating/Nickle Coating is to analyze surface, wear, friction Surface Analysis – Hardness calculations have been done almost the end of pin so just the Hardness of disc surface is to be calculated as opposed to Hardness. www.tjprc.org

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R. S. Mishra, Manoj Kumar Gupta* & Amit Khatri

Wear Analysis – Wear normally takes place at the pin tip that’s in circle shape. Pin mixed with disc handled with pre-treatment need to have decrease wear coefficient Friction Analysis – The pin blended disc subjected to pre-treatment to have lower friction coefficient.

ACKNOWLEDGEMENT The authors would really like to appreciate University for help through print publishing

NOMENCLATURE Fig.

Figure

mm

Millimeter

N

Newton

An

Ampere

V

Volt

Fe

Iron

Mn

Manganese

C

Carbon

S

Sulfur

P

Phosphorus

%

Percentage

Kg 3

Kilogram

M

Cubic meter

Pa

Pascal

J

Joule

K

Kelvin

°C

Degree Celcius

°

Degree (angle)

W

Weight / Load

Kgf

Kilogram force

Sec

Second

Min

Minute

Hr

Hour

Rpm

Revolution per minute

m/s

meter per second

C.O.F.

Coefficient of frictio

mTorr

Millitorr

DC

Direct current

kV

Kilo volt

mA

Milli ampere

MHz

Mega Hertz

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Hz

Hertz

µm

Micrometer

835

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