-
Materials Science and Engineering A 527 (2010) 60916097
Contents lists available at ScienceDirect
Materials Science and Engineering A
journa l homepage: www.e lsev ier .co
Therm t w
Yucel BirMaterials Instit
a r t i c l
Article history:Received 19 AAccepted 8 Jun
Keywords:Ferrous alloySemisolid procFatigue
deponderfatiguarly 5ent isl streble Cerebstimathe cr
1. Introdu
Hardfacimethods employed to enhance the wear and
corrosionoxidationresistance of surfaces [1]. Much effort has been
devoted to devel-oping alloys for hard facing applications. A
variety of Co-basedalloys are commercially available at present in
powder and wireform for hardfacing to extend the service life of
industrial compo-nents in wetheir hardndation resisone of theof
hardfacinis attributeM23C6 carbresistance bwhile refracvia
precipitintermetall
Stellite 6applicationwear and hwork tool stbeen testedunder
steeresults. How
Tel.: +90 2E-mail add
over. It ition
Among several advanced deposition techniques employedin cladding
wear resistant layers on tool materials, Plasma-Transferred Arc
(PTA) process stands out owing to a higherdeposition rate and lower
heat input and thus very low dilutionand distortion [16,36]. It has
thus been applied extensively in the
0921-5093/$ doi:10.1016/j.ar related applications [210].
Co-based alloys retainess and offer excellent thermal fatigue, wear
and oxi-tance at elevated temperatures [1116]. Stellite 6 ismost
common wear-resistant alloys for a wide rangeg applications. The
wear resistance of Stellite 6 alloyd to the high hardness provided
by Cr-rich M7C3 andides [12,17]. Cr also provides oxidation and
corrosiony forming an adherent oxide lm at high
temperaturestorymetals suchasMoandWcontribute to thestrengthation
hardening by forming MC and M6C carbides andic phases such as
Co3(Mo,W).
could be the very sought after solution for toolings in steel
thixoforming where thermal fatigue, abrasiveigh temperature
oxidation render the conventional hoteels entirely inadequate
[1822]. Stellite 6 has recentlyamong other materials [21,2335] as
monolithic die
l thixoforming conditions and showed encouragingever, cost
considerations favor coating hot work tool
62 6773084; fax: +90 262 6412309.ress:
[email protected].
deposition of coatings for wear and high temperature
applications[13,3739]. The present work was undertaken to
investigate theperformance of Stellite 6 coating deposited on
X32CrMoV33 hotwork tool steel via Plasma Transfer Arc (PTA) process
under steelthixoforming conditions.
2. Experimental procedure
Stellite 6 alloy powders fromDeloro Stellite Inc. with an
averagediameter of 163mwere deposited on 30mm-thick X32CrMoV33hot
work tool steel plates by the PTA overlaying process using
aCastolin Eutronic GAP400 P.T.A. unit. The metal powders
injectedfrom a powder feeder are melted inside the plasma arc ame
andthe melted metal powders thus obtained are deposited on
thesubstrate. The chemical compositions of the 3mm-thick
coatingthus obtained and the tool steel substrate are listed in
Table 1.The coated X32CrMoV33 samples were subsequently
austenizedat 1025 C for 30min, quenched in circulating air and
nally tem-pered twice at 625 C for 2h yielding a substrate hardness
of 45HRC. The clad layer was ground to a nal thickness of 2mm
toremove the surface imperfections. Non-destructive testing
(NDT)via radiography and eddy current testing was employed to
check
see front matter 2010 Elsevier B.V. All rights
reserved.msea.2010.06.015al fatigue testing of Stellite 6-coated
ho
ol
ute, Marmara Research Center, TUBITAK, Kocaeli, Turkey
e i n f o
pril 2010e 2010
essing
a b s t r a c t
The performance of Stellite 6 coatingArc (PTA) process was
investigated uvery favorable impact on the thermaltool steel
survivedmuch longer, for neon the coating. Thismarked improvemand
its ability to retain its mechanica6 alloy facilitated the
formation of staat the surface without spalling and thstresses
acting on the coating were eled to thermal fatigue cracking.
Onceminor.
ction
ng is one of the most attractive surface engineering
steelscationsconvenm/locate /msea
ork tool steel
sited on X32CrMoV33 hot work tool steel via Plasma Transfersteel
thixoforming conditions. The Stellite 6 coating made ae performance
of the hotwork tool steel. The coated hotwork000 cycles before the
rst thermal fatigue crackwas detectedattributed to thehigher
oxidation resistance of Stellite 6 alloyngth at elevated
temperatures. The Cr content of the Stelliter-rich oxides which
sustained the thermal stresses generatedy retarded crack
initiation. The peak compressive and tensileted to be 500MPa and
170MPa, respectively, and eventuallyack initiated, the impact of
microstructural features was only
2010 Elsevier B.V. All rights reserved.
employing high temperature alloys for tooling appli-s thus very
attractive to use Stellite 6 as hardfacing onal hot work tool
steels.
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6092 Y. Birol / Materials Science and Engineering A 527 (2010)
60916097
Table 1Chemical composition of the X32CrMoV33 hot work tool
steel and the PTA Stellite 6 coating.
Alloy C Si Mn Cr Mo Ni Al Co Cu Nb V W Fe
X32CrMoV3 5
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Y. Birol / Materials Science and Engineering A 527 (2010)
60916097 6093
Fig. 4. SEM mwork tool stee
level in thethe dilution
While anized at ovare identiesteel substrin a tempetype
structfusion line iapproximatmicroscopeication atdissipated bplanar
zonecellular regstantial inteby a columthe fusion lrest of the
cmeasured tacross thecin the deponess was mSDAS valuecoatings
[37
The rstfrom the liq
a) SEMarse aFig. 5. (of the coicrograph of (a) the interface
between the Stellite 6 coating and hotl substrate and (b) of the
coating at 500m from the interface.
present work is judged to be acceptable consideringlevels
previously reported for the PTA process [41].uniform ne scale
solidication structure is recog-
erview magnications (Fig. 2a), several distinct zonesd at still
higher resolutions (Figs. 2b and 4a). The toolate, which typically
consists of ne carbides dispersedred martensitic matrix, revealed a
lamellar, pearlitic-ure in the immediate vicinity of the fusion
line. Thes marked by a continuous planar zone, measured to beely
25mthick. This zone appears featureless at opticalresolutions (Fig.
2b). This is taken to imply that solid-the fusion line occurs very
rapidly as the heat input isy the underlying substrate almost
immediately. Thisis followed by a cellular region. The Fe content
in the
ion was found to be as high as 40wt% suggesting sub-rmixing. The
cellular region is replaced almost entirelynar dendritic structure
at approximately 50m fromine (Fig. 4b). Dendritic features are
predominant in theoating. The secondary dendrite arm spacing
(SDAS)waso be in the neighbourhood of 7m. The ne
structureoatingconrms the rapid solidicationprocess involvedsition
process [42,43]. The average as-deposited hard-easured to be
46013HV. Both the hardness and thes are in good agreement with
those reported for PTA,44].phase to form in the Stellite 6 coating
during coolinguid state is the primary Co-rich dendrites. The
remain-
ing liquid emixture ofsequence phard eutectEDS analysiThe
majoritally conformparticles inLikewise, Xposed of MM23C6 typeFe,
Ni, Si) a(Fig. 6). Theing, instead[47] is belieto dilution ethe
stability
Fig. 6. XRDmicrograph of the interdendritic carbides and (b) the
EDS analysisnd ne carbides marked in (a).
ventually solidies by a eutectic reaction into a lamellarCo-rich
phase and Cr-rich carbides. This solidicationroduces a Co-rich
solid solution dendritic matrix withic carbides at interdendritic
sites [43,45,46] (Fig. 5). Thes has shown the eutectic carbides to
be rich in Cr and Co.y of the coarser carbide particles were found
to gener-to the M7C3 stoichiometry while the smaller carbide
side the dendrites are likely to be of the M23C6 variety.RD
analysis has shown the coating to be mainly com-
7C3 carbides with an orthorhombic crystal structure,carbides
with an f.c.c. crystal structure (M=Co, Cr, W,nd Co-rich matrix
phase with an f.c.c. crystal structuref.c.c. structure of the
Co-based matrix of the hard fac-of the h.c.p. crystal structure of
the monolithic alloyved to be due to the Fe enrichment in the
coating dueffect of the deposition process. Fe is known to
promoteof the f.c.c. structure of the Co-rich matrix [13].
spectrum of the Stellite 6 coating before the thermal fatigue
test.
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6094 Y. Birol / Materials Science and Engineering A 527 (2010)
60916097
Fig. 7. (a) Chasample duringthe front and r
Typicalof the coatmaximum alite 6-coate580 C andthe set
peaatively smawhich is diheating andacross theas 205 C, 2sets up
the
hangcyclin
stanionsther
imatetherlliteen ththe c6 alFig. 8. Cthermal
be subcondit
Thebe estare thethe Stebetwetion ofStellitenge in temperature at
the front and rear faces of the Stellite 6-coatedthermal cycling
and (b) change in temperature difference betweenear faces.
thermal cycles recorded near the front and rear facesed hot work
tool steel are illustrated in Fig. 7a. Thend minimum temperatures
at the rear face of the Stel-d hot work tool steel sample were
measured to be486 C, respectively, while the front face went
throughk temperatures, 750 C and 450 C, every 30 s. This rel-ller
amplitude of the thermal cycle at the rear face,splaced to the
right due to an apparent delay in bothcooling of the rear face,
produces a temperature gap
section of the coated sample which becomes as large5 s into the
cycle (Fig. 7b). This temperature intervalrmal stresses at the
front face which were shown to
(Fig. 8). Comis warmer tthe coatingtensile streand 170MPthe room
tthey couldapplied in alite 6 coatinto be
relatiknowntobetemperatur
The respwith a serieits integrityof heat cheings [51]. Sat the
focalwhere heatchanges obmal cyclesin Cr-bearinhowever, tovive on
thwhat happ
Fig. 9. General view of the front face of Stellite 6-coated hot
work tool steele in thermal stresses generated at the front face
with time duringg of the Stellite 6-coated hot work tool steel
sample.
tial for monolithic Stellite 6 under steel thixoforming[40].mal
stresses generated inside the Stellite 6 coating cand from, surface
= (T)E(T)(T) [48] where and Emal expansion coefcient and the Youngs
modulus of6 coating, respectively and T is the temperature gape
front and rear faces of the sample given in Fig. 7b. Dilu-oating
with Fe is ignored and the E and values of theloy were used in the
estimation of the thermal stressespressive stresses are produced in
the coating when ithan the substrate and tensile stresses dominate
whencools below the substrate. The peak compressive andsses acting
on the coating are estimated to be 500MPaa, respectively. While
these stresses are safely belowemperature yield strength of the
Stellite 6 alloy [49],be seriously degrading, leading to coating
failure whencyclic fashion. Besides, the yield strength of the
Stel-g at the thixoforming temperature range is expectedvely lower
in spite of the fact that Stellite 6 alloy iscapableof retaining
itsmechanical strengthatelevatedes [50].onse to thermal cycling of
the Stellite 6 coating is showns ofmacrographs in Fig. 9. The
Stellite 6 coating retainedfor several thousand thermal cycles with
no evidence
cking or blistering often encountered in thin hard coat-light
colouring was noted after 1000 cycles particularlypoint of the ame,
i.e. at the centre of the front face,accumulation is maximum. The
colour and contrast
served on the coating with increasing number of ther-are best
accounted for by the progress of oxidationg alloys [52]. The
surface oxidation did not progress,
a point where the oxides scales could no longer sur-
e surface and thus start to spall off. This is exactlyened in
the X32CrMoV33 steel samples, the oxides
samples in the course of thermal cycling.
-
Y. Birol / Materials Science and Engineering A 527 (2010)
60916097 6095
Fig. 10. (a, b) work tool steel sample after 5000 thermal
cycles. Front face of the sampleafter (c) metal
of which wcycles [40].
The rstthermal cycthe microsccycling in bcycles
earliefacewhereIn fact, sevecoated facestandard m(Fig. 10c). Tthe
scale ofis thus judgIt is inferredcrack initiasurface owithey spall
ocrack nucle
The crac(Fig. 11a). Pto the axismicrostructthat crackgrowth
invcrack was tbides, showintoM23C6This procesume fractiominous
thaOxide scale and thermal fatigue cracks at the front face of the
Stellite 6-coated hotlographic polishing and (d) chemical
etching.ere already too thick after only a thousand thermal
crack was detected on the coating surface after 5000les. Since
the samples were checked thoroughly underope every 500 cycles and
only visually during thermaletween, the crack might have initiated
several hundredr. The crack was located at the very centre of the
frontsurface oxides are probably the thickest (Fig. 10a and b).ral
cracks of various sizeswere identied once the frontof the thermal
fatigue test sample was polished usingetallographic procedures to
remove the surface oxideshe crack opening at the surface is
relatively larger thanthe dendritic microstructure, i.e. SDAS (Fig.
10d) anded to be a serious threat to the integrity of the
coating.from Fig. 10b that oxidation has been instrumental in
tion. Surface scales induce considerable damage at theng to a
thermal expansionmismatch, particularlywhenff from the surface. The
latter was shown to introduceation sites in hot work tool steels
[40].k was found to traverse almost the entire coatingropagation
occurred perpendicular to the surface, i.e.of maximum stress,
suggesting that the impact ofural featureswas onlyminor.
SEMmicrographs suggestpropagation is not interdendritic.
Nevertheless, crackolved the fracture of interdendritic carbides
when theraversing the dendrite boundaries (Fig. 11b). M7C3 car-n
tobepresent in thehigh-Cr Stellite coatings transformcarbideswhen
exposed to high temperatures [5,5355].s is promoted under cyclic
loading leading to a high vol-n ofM23C6 carbides [56].M23C6
carbides aremore volu-nM7C3 carbides and promote cracking at
interdendritic Fig. 11. SEM micrograph showing the crack on
vertical section of the sample (a, b).
-
6096 Y. Birol / Materials Science and Engineering A 527 (2010)
60916097
Fig. 12. Changthe hot work t
sites [57]. Tfractures in
The hardcoated tooltest are shostarting froof the substwas
obtainewasmore oness of theincreasing dproducingsteel substrthe
interfachard coatinbination ancoating. Whcoatings whof the
coatiningly softerincreasinglytensile strethe magnitumore
substexpansion m
It is fairperformancbetter withcompares vperformancber of
factoindeed very20wt%, oximal cycling[61,62]. Oxiing, stable
oenvironmenat the surfacretard crackpartly respoStellite 6-co
4. Conclus
Stellite 6via Plasma
its thermal fatigue performance. The coated hot work tool
steelsurvived steel thixoforming conditions much longer, for
nearly5000 cycles before the rst thermal fatigue crack was detected
onthe coating. This marked improvement is attributed to the
higher
ion rnicalllitesustaallingon. Twe
entuthe i
wled
lageyandby T
nces
. Atondfacinrook,ogy, vaghuashanavi Bh(2008. Chia.
Yaoashanendrz. 29 (2iu, M.. AntoDavispose MShin,126adu, Dadu,
DAoh,. Hou,ugsch000)uens06) 69. Oma5
(20LugscharmetSemi-Telle,695irol, Sirol, Se in hardness across the
interface between the Stellite 6 coating andool steel substrate
with increasing number of thermal fatigue cycles.
he crack morphology in Fig. 11 suggests that such localdeed
occurred and get connected to the growing crack.ness measurements
across the section of the Stellite 6-steel samples at various
stages of the thermal fatiguewn in Fig. 12. Hardnessmeasurements
were performedm the surface of the coating until the hardness
levelrate tool steel measured before the thermal fatigue testd. One
can see that the hardness of the Stellite 6 coatingr less retained
during the thermal fatigue test. The hard-tool steel substrate, on
the other hand, decreased withepth from the surface after the rst
500 thermal cyclesa hard coating on a relatively soft substrate.
The toolate softened further opening the hardness gap acrosse with
increasing number of thermal cycles (Fig. 12). Ag on a relatively
soft substrate is not a desirable com-d is known to be a serious
risk for the integrity of theile this is not as critical for
overlay coatings as for PVDere the substrate support is essential
for the integrityg, it could nevertheless present problems. The
increas-substrate inevitably responds to thermal stresses bylarger
strains. This, in turn, would put an additional
ss component on the coating due to the mismatch inde of the
respective plastic strains. This could be much
antial than the thermal strains produced by the
thermalismatch.
to conclude from the foregoing that the thermal fatiguee of the
Stellite 6-coated hot work tool steel is muchrespect to the
uncoated hot work tool steel and alsoery favourably to the
monolithic Stellite 6 alloy. Thise of the coated sample can be
attributed to a num-
oxidatmechathe Stewhichout spinitiaticoatingand evtiated,
Ackno
F. Aimentsfunded
Refere
[1] K.CHar
[2] P. Cnol
[3] D. R[4] H. K[5] R. R
29[6] K.A[7] M.X[8] H. K[9] R. J
Des[10] R. L[11] K.C[12] J.R.
Pur[13] J.C.
117[14] I. R[15] I. R[16] J.N.[17] Q.Y[18] E. L
2 (2[19] S. M
(20[20] M.Z
A39[21] E.
Chion
[22] R.690
[23] Y. B[24] Y. Brs. The higher oxidation resistance of
Stellite 6 alloy, ishelpful [13,16,40,5860].With a Cr content well
abovede lms formed on the Stellite 6 coatings during ther-are
expected to be Cr-rich (Cr,Co,Fe)2O3 type oxidesdes of this type
are well established to be slowly grow-xides and act as a
protective layer in highly corrosivets [52]. They can sustain the
thermal stresses generatedewithout spalling owing to their
plasticity and therebyinitiation [63,64]. The stable hardness of
the coating isnsible for the superior thermal fatigue resistance of
theated hot work tool steel.
ion
coating deposited on X32CrMoV33 hot work tool steelTransfer Arc
process made a very favorable impact on
[25] Y. Birol, I[26] A. Rassili,
AlexandrInternati(S2P), Lim
[27] P. KapranProceedinof Alloys306311
[28] R. Kopp,Z. MituraConferen
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Birol, I[36] J.N. Aoh,esistance of Stellite 6 alloy and its ability
to retain itsstrength at elevated temperatures. The Cr content of6
alloy facilitated the formation of stable Cr-rich oxidesined the
thermal stresses generated at the surfacewith-owing to their
plasticity and thereby retarded crack
he peak compressive and tensile stresses acting on there
estimated to be 500MPa and 170MPa, respectively,ally led to thermal
fatigue cracking. Once the crack ini-mpact of microstructural
features was only minor.
gements
ik and O. Cakr are thanked for their help in the exper-KOBATEK
for coating tool steel samples. This work wasUBITAK.
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Thermal fatigue testing of Stellite 6-coated hot work tool
steelIntroductionExperimental procedureResults and
discussionConclusionAcknowledgementsReferences